Inspection

MAINSHAFT AND GEAR

Inspection

MAINSHAFT AND GEAR
If the contact surface on each gear and mainshaft. has damage, peeling, abrasion, dent, bent, or any other damage, replace the components.






SYNCHRONIZER

Synchronizer Hub and Coupling Sleeve
- If the contact surface on coupling sleeve, synchronizer hub and shifting insert has damage or abrasion, replace the components.
- Coupling sleeve and synchronizer hub shall move smoothly.






Bulk Ring and Spread Spring
- If the cam surface on baulk ring or contact surface on insert has damage or excessive wear, replace with a new one.
- If spread spring is damaged, replace with a new one.






Bulk Ring Clearance for Single Cone Synchronizer (6th and Reverse)
Press baulk ring on the cone and measure the clearance between baulk ring and cone. If the measurement is below limit, replace it with a new one.

Clearance
Standard value : Refer to Baulk Ring Clearance
Limit value : Refer to Baulk Ring Clearance





Bulk Ring Clearance for Triple Cone Synchronizer (1st and 2nd)
Check the clearance between outer baulk ring (1), synchronizer cone (2), and inner baulk ring (3) as follows.

CAUTION:
The clearances "A", "B" and "C" are controlled with outer baulk ring, synchronizer cone, and inner baulk ring as a set. Replace them as a set if the clearances are outside the limit value.





1. Measure the clearance "A" at 2 points or more diagonally opposite using a feeler gauge (B) when pressing outer baulk ring (1), synchronizer cone (2), and inner baulk ring (3) toward gear taper cone (C). And then calculate mean value.

Clearance "A"
Standard value : Refer to Baulk Ring Clearance
Limit value : Refer to Baulk Ring Clearance





2. Measure the clearance "B" at 2 points or more diagonally opposite using a feeler gauge (A). And then calculate mean value.





Clearance "B"
Standard value : Refer to Baulk Ring Clearance
Limit value : Refer to Baulk Ring Clearance





3. Measure the clearance "C" at 2 points or more diagonally opposite using a feeler gauge (A) when pressing outer baulk ring (1), synchronizer cone (2), and inner baulk ring (3) toward gear taper cone (B). And then calculate mean value.

Clearance "C"
Standard value : Refer to Baulk Ring Clearance
Limit value : Refer to Baulk Ring Clearance





Bearing
If the bearing does not rotate smoothly or the contact surface on ball or race is damaged or peeled, replace with new ones.