Input Shaft Inspection

INPUT SHAFT COMPONENT PARTS INSPECTION





1. Inspect 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 corpse. Lightly rub the synchronizer ring and gear cone together.

NOTICE: 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 inch).
If the clearance is less than the minimum, replace the synchronizer ring and gear cone by applying a small amount of fine lapping compound.

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





2. Inspect 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 inch).
If the clearance exceeds the maximum, replace the 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: 24.870 mm (0.97Y1 inch).
Part B: 28.970 mm (1.1405 inch).
Part C: 30.970 mm (1.2193 inch).
Part D: 24.970 mm (0.9831 inch).
- 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 inch).
If the runout exceeds the maximum, replace the input shaft.