Inspection of Transmission Components

1. INSPECT INPUT SHAFT
a. Using a micrometer, measure the outer diameter of the input shaft journal surface.

Minimum outer diameter:
Part A 24.870 mm (0.9791 in.) (C150)
B 28.970 mm (1.1405 in.)
C 30.970 mm (1.2193 in.)
D 24.970 mm (0.9831 in.)




b. Using a dial indicator, check the shaft runout.

Maximum runout: 0.05 mm (0.0020 in.)




2. INSPECT OUTPUT SHAFT
a. Using a micrometer, measure the outer diameter of the output shaft journal surface.

Minimum outer diameter:
Part A 32.970 mm (1.2980 in.)
B 37.970 mm (1.4949 in.)
C 31.970 mm (1.2587 in.)




b. Using a dial indicator, check the shaft runout.

Maximum runout: 0.05 mm (0.0020 in.)




3. CHECK OIL CLEARANCE OF EACH GEAR
Using a dial indicator, measure the oil clearance between the gear and input or output shaft with the needle roller bearing installed.

Standard clearance: 0.015 - 0.058 mm (0.0006 - 0.0023 in.)
Maximum clearance: 0.07 mm (0.0028 in.)

If the clearance exceeds the limit, replace the gear, needle roller bearing or shaft.




4. INSPECT SYNCHRONIZER RINGS
a. Turn the ring and push it in to check the braking action.




b. Measure the clearance between the synchronizer ring back and the gear spline end.

Minimum clearance: 0.6 mm (0.024 in.)

If the clearance is less than the limit, replace the synchronizer ring.




5. MEASURE CLEARANCE OF SHIFT FORKS AND HUB SLEEVES
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.




6. IF NECESSARY, REPLACE INPUT SHAFT FRONT BEARING
a. Using SST, pull out the bearing.
SST 09612-65014 (09612-01040, 09612-01050 09612-01060)




b. Using SST, press in a new bearing.
SST 09310-35010




7. IF NECESSARY, REPLACE OUTPUT SHAFT FRONT BEARING
a. Remove the bolt and bearing lock plate.
b. Using SST, pull out the bearing.
SST 09308-00010




c. Using SST, press in a new bearing.
SST 09310-35010
d. Install the bearing lock plate and torque the bolt.

Torque: 115 kg-cm (8 ft-lb, 11 N-m)




8. IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL SEAL
a. Remove the input shaft front bearing.
b. Using SST, pull out the oil seal.
SST 09308-00010




c. Using SST, drive in a new oil seal.
SST 09608-12010 (09608-00020, 09608-00040)

Drive in depth: 15.6 - 16.0 mm (0.614 - 0.630 in.)

d. Coat the lip of the oil seal with MP grease.
e. install the input shaft front bearing.




9. IF NECESSARY, REPLACE LH SIDE OIL SEAL
a. Drive out the oil seal with a screwdriver.




b. Using SST, drive in a new oil seal.
SST 09350-32014 (09351-32111, 09351-32130)

Drive in depth: 2.1 - 2.7 mm (0.083 - 0.106 in.)

c. Coat the lip of the oil seal with MP grease.




10. IF NECESSARY, REPLACE RH SIDE OIL SEAL
a. Drive out the oil seal with a screwdriver.




b. Using SST, drive in a new oil seal.
SST 09350-32014 (09351-32130, 09351-32150)

Drive in depth: 1.6 - 2.2 mm (0.063 - 0.087 in.)

c. Coat the lip of the oil seal with MP grease.




11. IF NECESSARY, REPLACE LH OUTER RACE OF SIDE BEARING
a. Using SST, pull out the outer race and shim.
SST 09612-65014 (09612-01040, 09612-01050 09612-01060)
b. Place the shim into the case.




c. Using SST, drive in a new outer race.
SST 09608-20012 (09608-03020, 09608-03090)




12. IF NECESSARY, REPLACE RH OUTER RACE OF SIDE BEARING
a. Using SST, pull out the outer race and shim.
SST 09612-65014 (09612-01040, 09612-01050 09612-01060)
b. Place the shim into the case.




c. Using SST, drive in a new outer race.
SST 09608-20012 (09608-03020, 09608-03060)




13. IF NECESSARY, REPLACE CONTROL SHAFT COVER OIL SEAL
a. Using a screwdriver, pry out the oil seal.




b. Using a socket wrench and hammer, drive in a new oil seal.

Drive in depth: 1.0 - 2.0 mm (0.039 - 0.079 in.)

c. Coat the lip of the oil seal with MP grease.




14. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN GEAR OIL SEAL
a. Using SST, pull out the oil seal.
SST 09921-00010




b. Using SST, drive in a new oil seal.
SST 09201-60011

Drive in depth: 25 mm (0.98 in.)




15. (C150)
IF NECESSARY, REPLACE REVERSE RESTRICT PIN
a. Using SST, remove the straight screw plug.
SST 09313-30021




b. Using a pin punch and hammer, drive out the slotted spring pin.




c. Replace the reverse restrict pin.
d. Drive in the slotted spring pin.
e. Apply sealant to the plug threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent
f. Using SST, install the straight screw plug.
SST 09313-30021

Torque: 200 kg-cm (14 ft-lb, 20 N-m)