Shift Forks Clearance Inspection
InspectionNOTE: If replacement is required, always replace the synchro sleeve and hub as a set.
1. Measure the clearance between the each shift fork (A) and its matching synchro sleeve (B). If the clearance exceeds the service limit, go to step 2.
Standard: 0.35 - 0.65 mm (0.014 - 0.026 inch)
Service Limit: 1.00 mm (0.039 inch)
2. Measure the thickness of the shift fork fingers.
^ If the thickness of the shift fork finger is less than the standard, replace the shift fork with a new one.
^ If the thickness of the shift fork finger is within the standard, replace the synchro sleeve with a new one.
Standard:
1-2 Shift Fork: 7.4 - 7.6 mm (0.29 - 0.30 inch)
3-4, 5-6, Reverse Shift Fork: 6.2 - 6.4 mm (0.24 - 0.25 inch)
3. Measure the clearance between each shift fork, reverse shift piece and shift arm A. If the clearance exceeds the service limit, go to step 4.
Standard: 0.2 - 0.6 mm (0.008 - 0.024 inch)
Service Limit: 0.7 mm (0.028 inch)
4. Measure the width of the shift arm A.
^ If the width of the shift arm A is less than the service limit, replace the shift arm A with a new one.
^ If the width of the shift arm A is within the service limit, replace the shift fork or the reverse shift piece with a new one.
Standard: 16.8 - 17.0 mm (0.661 - 0.669 inch)
Service Limit: 16.7 mm (0.657 inch)
5. Measure the clearance between the 1-2 shift lever and each shift fork and shift piece. If the clearance exceeds the service limit, go to step 6.
Standard: 0 - 0.4 mm (0 - 0.016 inch)
Service Limit: 0.5 mm (0.020 inch)
6. Measure the width of the 1-2 shift lever.
^ If the width of the 1-2 shift lever is less than the service limit, replace the 1-2 shift lever with a new one.
^ If the width of the 1-2 shift lever is within the service limit, replace the shift fork or shift piece with a new one.
Standard: 17.0 - 17.2 mm (0.669 - 0.677 inch)
Service Limit: 16.9 mm (0.665 inch)