Output Shaft

EB60 MANUAL TRANSMISSION / TRANSAXLE: OUTPUT SHAFT: INSPECTION

1. INSPECT 1ST GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 1st gear thrust clearance.





Standard clearance:

0.23 to 0.37 mm (0.00906 to 0.0145 in.)

Maximum clearance:

0.37 mm (0.0145 in.)

If the clearance is more than the maximum, replace the No. 1 transmission clutch hub, 1st gear bush or 1st gear. Replace the part or parts determined to be the most likely cause of the problem.

2. INSPECT 2ND GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 2nd gear thrust clearance.





Standard clearance:

0.16 to 0.33 mm (0.00630 to 0.0129 in.)

Maximum clearance:

0.33 mm (0.0129 in.)

If the clearance is more than the maximum, replace the inner 2nd gear bearing race, No. 1 transmission clutch hub, 2nd gear or 3rd driven gear. Replace the part or parts determined to be the most likely cause of the problem.

3. INSPECT 1ST GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 1st gear radial clearance.





Standard clearance:

0.009 to 0.047 mm (0.000355 to 0.00185 in.)

Maximum clearance:

0.047 mm (0.00185 in.)

If the clearance is more than the maximum, replace the 1st gear, 1st gear needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

4. INSPECT 2ND GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 2nd gear radial clearance.





Standard clearance:

0.009 to 0.047 mm (0.000355 to 0.00185 in.)

Maximum clearance:

0.047 mm (0.00185 in.)

If the clearance is more than the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

5. INSPECT OUTPUT SHAFT

(a) Using a dial indicator and 2 V-blocks, measure the output shaft runout.





Maximum runout:

0.03 mm (0.00118 in.)

If the runout is more than the maximum, replace the output shaft.

(b) Using a micrometer, measure the outer diameter of the output shaft journal surface at the locations indicated.





Standard outer diameter:

Part A
28.010 to 28.023 mm (1.10276 to 1.10326 in.)

Part B
42.180 to 42.200 mm (1.66063 to 1.66141 in.)

Part C
36.010 to 36.026 mm (1.41772 to 1.41834 in.)

Minimum outer diameter:

Part A
28.010 mm (1.10276 in.)

Part B
42.180 mm (1.66063 in.)

Part C
36.010 mm (1.41772 in.)

If the outer diameter is less than the minimum, replace the output shaft.

6. INSPECT 1ST GEAR

(a) Using a cylinder gauge, measure the inside diameter of the 1st gear.





Standard inside diameter:

57.909 to 57.925 mm (2.27988 to 2.28050 in.)

Maximum inside diameter:

57.925 mm (2.228050 in.)

If the inside diameter is more than the maximum, replace the 1st gear.

7. INSPECT 2ND GEAR

(a) Using a cylinder gauge, measure the inside diameter of the 2nd gear.





Standard inside diameter:

57.909 to 57.925 mm (2.27988 to 2.28050 in.)

Maximum inside diameter:

57.925 mm (2.28050 in.)

If the inside diameter is more than the maximum, replace the 2nd gear.

8. INSPECT 1ST GEAR BUSH

(a) Using a micrometer, measure the outer diameter of the 1st gear bush.





Standard outer diameter:

51.89 to 51.90 mm (2.04291 to 2.04330 in.)

Minimum outer diameter:

51.89 mm (2.04291 in.)

If the outer diameter is less than the minimum, replace the 1st gear bush.

(b) Using a cylinder gauge, measure the inside diameter of the 1st gear bush.





Standard inside diameter:

42.200 to 42.215 mm (1.66142 to 1.66200 in.)

Maximum inside diameter:

42.215 mm (1.66200 in.)

If the inside diameter is more than the maximum, replace the 1st gear bush.

9. INSPECT INNER 2ND GEAR BEARING RACE

(a) Using a micrometer, measure the outer diameter of the inner 2nd gear bearing race.





Standard outer diameter:

51.89 to 51.90 mm (2.04291 to 2.04330 in.)

Minimum outer diameter:

51.89 mm (2.04291 in.)

If the outer diameter is less than the minimum, replace the inner 2nd gear bearing race.

(b) Using a cylinder gauge, measure the inside diameter of the inner 2nd gear bearing race.





Standard inside diameter:

42.200 to 42.215 mm (1.66142 to 1.66200 in.)

Maximum inside diameter:

42.215 mm (1.66200 in.)

If the inside diameter is more than the maximum, replace the inner 2nd gear bearing race.

10. INSPECT NO. 1 SYNCHRONIZER RING SET (for 1st Gear)

(a) Check for wear and damage.

(b) Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.





Text in Illustration





(c) Install the inner ring to the 1st gear.

(d) Install the middle ring to the 1st gear.

(e) Install the outer ring to the 1st gear.

(f) Turn the synchronizer ring in both directions while pushing it against the 1st gear cone and check that it locks in both directions.





Text in Illustration





If the synchronizer ring set does not lock, replace the synchronizer ring set.

(g) Using a feeler gauge, measure the clearance between the synchronizer ring set and gear spline end.





Standard clearance:

0.88 to 1.72 mm (0.0347 to 0.0677 in.)

Minimum clearance:

0.88 mm (0.0347 in.)

If the clearance is less than the minimum, replace the synchronizer ring set.

11. INSPECT NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)

(a) Check for wear and damage.

(b) Coat the 2nd gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.





Text in Illustration





(c) Install the inner ring to the 2nd gear.

(d) Install the middle ring to the 2nd gear.

(e) Install the outer ring to the 2nd gear.

(f) Turn the synchronizer ring in both directions while pushing it against the 2nd gear cone and check that it locks in both directions.





Text in Illustration





If the synchronizer ring set does not lock, replace the synchronizer ring set.

(g) Using a feeler gauge, measure the clearance between the synchronizer ring set and gear spline end.





Standard clearance:

0.88 to 1.72 mm (0.0347 to 0.0677 in.)

Minimum clearance:

0.88 mm (0.0347 in.)

If the clearance is less than the minimum, replace the synchronizer ring set.

12. INSPECT REVERSE GEAR

(a) Using a vernier caliper, measure the width of the reverse gear groove (A) and the thickness of the claw part on the No. 1 gear shift fork shaft assembly (B), and then calculate the clearance.





Standard clearance (A - B):

0.1 to 0.5 mm (0.00394 to 0.0196 in.)

If the clearance is not as specified, replace the reverse gear and No. 1 gear shift fork shaft assembly.

13. INSPECT NO. 1 TRANSMISSION CLUTCH HUB

(a) Check that the No. 1 transmission clutch hub and reverse gear slide smoothly.





(b) Check that the edges of the reverse gear spline gear are not worn down.