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 26.970 mm (1.0618 in.)
B 32.470 mm (1.2783 in.)
C 33.090 mm (1.3028 in.)
D 29.970 mm (1.1799 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 31.970 mm (1.2587 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:
1st, 2nd, 3rd and 4th gears 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
5th gear 0.009 - 0.050 mm (0.0004 - 0.0020 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
If the clearance exceeds the limit, replace the gear, needle roller bearing or shaft.

Note: For vehicles produced prior to 4/90, 3rd gear, hub sleeve no.2, synchronizer no.2 and shift fork no.2 must be replaced as a set if any one of those components needs to be replaced. Refer to Technical Service Bulletin No. TC95-003.




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. Remove the bolt and transaxle case oil receiver.
b. Using SST, pull out the bearing.
SST 09308-00010




c. Using SST, press in a new bearing.
SST 09310-35010
d. Install the transaxle case oil receiver and torque the bolt.
Torque: 75 kg-cm (65 in.-lb, 7.4 N.m)




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: 185 kg-cm (13 ft-lb, 18 N.m)




8. IF NECESSARY, REPLACE INPUT SHAFT FRONT OIL SEAL
a. Using a screwdriver, pry out the oil seal.




b. Using SST, drive in a new oil seal.
SST 09608-20012 (09608-00080, 09608-03020)
Drive in depth: 1.0 - 2.0 mm (0.039 - 0.079 in.)
c. Coat the lip of the oil seal with MP grease.




9. IF NECESSARY, REPLACE LH SIDE OIL SEAL
a. Using SST, press out the oil seal from the retainer.
SST 09608-20012 (09608-00030, 09608-03020)




b. Using SST, press in a new oil seal until its surface is flush with the case surface.
SST 09316-60010(09316-00010)
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 until its surface is flush with the case surface.
SST 09316-60010 (09316-00010)
c. Coat the lip of the oil seal with MP grease.




11. IF NECESSARY, REPLACE LH OUTER RACE OF SIDE BEARING
a. Using SST, press out the outer race.
SST 09608-20012 (09608-00060, 09608-03020)
b. Install the bearing retainer without an O-ring.
c. Install and torque the retainer bolts.
Torque: 185 kg-cm (13 ft-lb, 18 N.m)
d. Place the thinnest shim into the case.




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




12. IF NECESSARY, REPLACE RH OUTER RACE OF SIDE BEARING
a. Using SST, press out the outer race and shim.
SST 09608-20012 (09608-00030, 09608-03020)




b. Place the shim into the case.
c. Using SST, press 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 SST, drive in a new oil seal until its surface is flush with the cover surface.
SST 09608-20012 (09608-00080, 09608-03020)
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: 19 mm (0.75 in.)




15. 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: 130 kg-cm (9 ft-lb, 13 N.m)