Inspection of Output Shaft Component Parts

1. INSPECT SYNCHRONIZER RINGS
a. Check for wear or damage.
b. Turn the ring and push it in to check the braking action.




c. Measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.6 mm (0.024 in.)
If the clearance is less than the limit, replace the synchronizer ring.




2. MEASURE CLEARANCE OF NO.1 SHIFT FORK AND HUB SLEEVE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the limit, replace the shift fork or hub sleeve.




3. INSPECT OUTPUT SHAFT
a. Check the output shaft for wear or damage.
b. Using a micrometer, measure the outer diameter of the second gear bushing and output shaft journal surface.
Minimum outer diameter: 38.950 mm (1.5335 in.)




c. Using a dial indicator, check the shaft runout.
Maximum runout: 0.060 mm (0.0024 in.)




4. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING
a. Using SST and a press, remove the bearing.
SST 09307-12010, 09950-00020




b. Using SST and a press, install a new bearing.
SST 09316-60010 (09316-00070)