Transaxle Unit
C59 MANUAL TRANSAXLE: MANUAL TRANSAXLE UNIT:
INSPECTION
1. INSPECT 5TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 5th gear thrust clearance.
5th gear thrust clearance:
2. INSPECT 5TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 5th gear radial clearance.
5th gear radial clearance:
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
3. INSPECT SYNCHRONIZER RING NO. 3
(a) Check for wear or damage.
(b) Coat the 5th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 5th gear cone. Check that the ring locks.
If the synchronizer ring does not lock, replace the ring or the 5th gear.
(c) Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance:
0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchronizer ring and gear.
4. INSPECT TRANSMISSION HUB SLEEVE NO. 3
(a) Check the sliding condition between the transmission hub sleeve No. 3 and transmission clutch hub No. 3.
(b) Check that the tip of the spline gear of the transmission hub sleeve No. 3 is not worn down.
(c) Using vernier calipers, measure the width of the transmission hub sleeve No. 3 groove (A) and the thickness of the claw part on the gear shift fork No. 3 (B), and calculate the clearance.
Standard clearance (A - B):
0.3 to 0.5 mm (0.012 to 0.0197 in.)
If the clearance is out of specification, replace the transmission hub sleeve No. 3 and gear shift fork No. 3.
5. INSPECT 5TH GEAR
(a) Using a caliper gauge, inspect the 5th gear as shown in the illustration.
5th gear inner diameter:
If the inner diameter exceeds the maximum, replace the 5th gear.
6. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY
(a) Using a caliper gauge, inspect the reverse idler gear sub-assembly as shown in the illustration.
Reverse idler gear sub-assembly inner diameter::
If the inner diameter exceeds the maximum, replace the reverse idler gear sub-assembly.
(b) Using a micrometer, inspect the reverse idler gear shaft as shown in the illustration.
Reverse idler gear shaft outer diameter:
If the outer diameter is less than the minimum, replace the reverse idler gear shaft.