Input Shaft Components Inspection

1. INSPECT SYNCHRONIZER RINGS
a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of fine lapping compound between the synchronizer ring and gear cone.
Lightly rub the synchronizer ring and gear cone together.

NOTE: Ensure the fine lapping compound is completely washed off after rubbing.

c. Check again the braking effect of the synchronizer ring.
d. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

Minimum clearance: 0.6 mm (0.024 in.)

HINT :
- When replacing either a synchronizer ring or gear, apply a small amount of fine lapping compound between the synchronizer ring and gear cone.
Lightly rub the synchronizer ring and gear cone together.
- When replacing both the synchronizer ring and gear, there is no need to apply any compound or to rub them together.

NOTE: Ensure the fine lapping compound is completely washed off after rubbing.




2. INSPECT CLEARANCE OF NO.2 SHIFT FORK AND HUB SLEEVE
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 maximum, replace shift fork or hub sleeve.




3. INSPECT INPUT SHAFT
a. Check the input shaft for wear or damage.
b. Using a micrometer, measure the outer diameter of the input shaft journal surface.

Minimum outer diameter:
Part A 26.970 mm (1.0618 in.)
Part B 32.470 mm (1.2783 in.)
Part C 33.090 mm (1.3028 in.)
Part D 29.970 mm (1.1799 in.)

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




c. Using a dial indicator, check the shaft runout.

Maximum runout: 0.05 mm (0.0020 in.)

If the outer diameter exceeds the maximum, replace the input shaft.