With All Wheel Drive
Inspect all parts and repair or replace as necessary.
Gears (1st, 2nd, 3rd, 4th)
1. Inspect the synchronizer cones for wear.
2. Inspect the individual gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer ring matching teeth for damage and wear.
Synchronizer ring, gear (1st, 2nd, 3rd, 4th)
1. Inspect the individual synchronizer ring teeth for damage, wear, and cracks.
2. Inspect the taper surface for wear and cracks.
NOTE: Set the synchronizer ring squarely in the gear; then measure around the circumference.
3. Measure the clearance between the synchronizer ring and flank surface of the gear.
Standard clearance: 1.02 - 1.98 mm (0.040 - 0.078 in.)
Minimum: 0.5 mm (0.020 in.)
Clutch hub assembly
1. Inspect the clutch hub sleeve and hub operation.
2. Inspect the individual gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer keys for damage, wear, and cracks.
Shift fork
1. Measure the clearance between hub sleeve and shift fork.
Reverse idler gear and reverse lever
1. Inspect gear teeth for damage, wear, and cracks.
2. Measure the clearance between the reverse idler gear bushing and the reverse lever.
Standard clearance: 0.095 - 0.345 mm (0.0037 - 0.0136 in.)
Maximum: 0.845 mm (0.0333 in.)
Bearing
1. Inspect for damage and rough rotation.
Primary Shaft and Secondary Shaft
1. Inspect the gear contact surface for damage and wear.
2. Inspect the splines for damage and wear.
3. Inspect the gear teeth for damage, wear, and cracks.
4. Inspect the oil passage for clogging.
5. Inspect the shaft gear runout.
Primary shaft gear runout: 0.05 mm (0.002 in.)
Secondary shaft gear runout: 0.015 mm (0.0006 in.)
NOTE: If the shaft gear is replaced, adjust the bearing preload.
6. Oil clearance between shaft gears and gears.
Differential Lock Gear Sleeve
1. Measure the clearance between the gear sleeve groove and shift fork.
Standard clearance: 0.1 5 - 0.50 mm (0.006 - 0.02 in.)
Maximum: 1.0 mm (0.394 in.)
2. Inspect for damage and rough rotation.