Inspection of Output Shaft Component Parts

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 is locks. If the braking effect is insufficient, lightly rub the synchronizer ring and gear cone by applying a small amount of fine lapping compound.

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

Check again the braking effect of the synchronizer ring.




c. Measure the clearance between the synchronizer ring back and gear spline end.

Minimum clearance: 0.6 mm (0.024 in.)

If the clearance is less than the limit, replace the synchronizer ring and gear cone.

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




2. INSPECT 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 maximum, replace the shift fork or hub sleeve.




3. INSPECT OUTPUT SHAFT
a. Using a micrometer, measure the outer diameter of the output shaft journal surface.

Minimum outer diameter:
Part A 32.970 mm (1.2980 in.)
Part B 37.970 mm (1.4949 in.)
Part C 31.970 mm (1.2587 in.)

If the outer diameter exceeds the minimum, replace the output shaft.




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

Maximum runout: 0.05 mm (0.0020 in.)

If the runout exceeds the maximum, replace the output shaft.