Output Shaft Component Parts Inspection

1. INSPECT 1ST GEAR SYNCHRONIZER RING
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. If it does not lock, replace 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.)

- 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 2ND GEAR SYNCHRONIZER RING
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 it does not lock, replace the synchronizer ring.




c. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

Minimum clearance: 0.7 mm (0.028 in.)

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




3. MEASURE NO.1 SHIFT FORK AND HUB SLEEVE CLEARANCE
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 limit, replace the shift fork or hub sleeve.




4. INSPECT OUTPUT SHAFT
a. Check the output shaft for wear or damage.
b. Using a micrometer, measure the outer diameter of the output shaft journal surface.

Minimum outer diameter: 38.950 mm (1.5335 in.)




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

Maximum runout: 0.06 mm (0.0024 in.)