Input Shaft

E351 MANUAL TRANSAXLE: INPUT SHAFT:

INSPECTION

1. INSPECT 4TH GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the 4th gear thrust clearance.
Standard clearance:
0.10 to 0.57 mm (0.0039 to 0.0224 in.)
If clearance is out of specification, replace the transmission clutch hub No.2, 4th gear or input shaft rear radial ball bearing.
2. INSPECT 3RD GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 3rd gear thrust clearance.
Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
If clearance is out of specification, replace the transmission clutch hub No.2, 3rd gear or input shaft.
3. INSPECT 4TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 4th gear radial clearance.
Standard clearance:
mm (in.)

If clearance is out of specification, replace the 4th gear, needle roller bearing or input shaft.
4. INSPECT 3RD GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 3rd gear radial clearance.
Standard clearance:
mm (in.)

If clearance is out of specification, replace the 3rd gear, needle roller bearing or input shaft.
5. INSPECT INPUT SHAFT

(a) Using a V-block and dial indicator, inspect the shaft for runout.
Maximum runout:
0.03 mm (0.0012 in.)
If runout exceeds the maximum, replace the input shaft.

(b) Using a micrometer, measure the outside diameter of the input shaft journal surface.
Outside diameter:
mm (in.)

If the outside diameter is less than the minimum, replace the input shaft.
6. INSPECT 4TH GEAR

(a) Using a cylinder gauge, measure the inside diameter of the 4th gear.
Inside diameter:
mm (in.)

If the inside diameter exceeds the maximum, replace the 4th gear.
7. INSPECT 3RD GEAR

(a) Using a cylinder gauge, measure the inside diameter of the 3rd gear.
Inside diameter:
mm (in.)

If the inside diameter exceeds the maximum, replace the 3rd gear.
8. INSPECT 2ND SYNCHRONIZER OUTER RING

(a) Coat the 4th gear cone with gear oil. Turn the 2nd synchronizer outer ring (synchronizer ring No.4) in one direction while pushing it against the 4th gear cone. Check that the ring locks.
If the 2rd synchronizer outer ring does not lock, replace the ring or the 4th gear.

(b) Using a feeler gauge, measure the clearance between the synchronizer outer ring (synchronizer ring No.4) back and 4th gear spline end.
Standard clearance:
0.75 to 1.65 mm (0.0295 to 0.0650 in.)
If clearance is out of specification, replace the synchronizer ring.
9. INSPECT SYNCHRONIZER RING NO.3

(a) Coat the 3rd gear cone with gear oil. Turn the synchronizer outer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks.
If the synchronizer outer ring does not lock, replace the ring or the 3rd gear.

(b) Using a feeler gauge, measure the clearance between the synchronizer ring No.3 back and 3rd gear spline end.
Standard clearance:
0.65 to 1.75 mm (0.0256 to 0.0689 in.)
If clearance is out of specification, replace the synchronizer ring No.3.
10. INSPECT TRANSMISSION HUB SLEEVE NO.2

(a) Inspect the sliding condition between the transmission hub sleeve No.2 and transmission clutch hub No.2.
(b) Inspect the tip of the spline gear on the transmission hub sleeve No.2 for wear.
If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.

(c) Using vernier calipers, measure the width of the transmission hub sleeve No.3 groove and the thickness of the claw part on the gear shift fork No.1, and calculate the clearance.
Standard clearance:
0.11 to 0.69 mm (0.0043 to 0.0272 in.) {A - B}
If clearance is out of specification, replace the transmission hub sleeve No.2 and gear shift fork No.2 with new ones.
11. INSPECT 3RD GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 3rd gear radial clearance.
Standard clearance:
mm (in.)

If clearance is out of specification, replace the 3rd gear, needle roller bearing or input shaft.
12. INSPECT 4TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 4th gear radial clearance.
Standard clearance:
mm (in.)

If clearance is out of specification, replace the 4th gear, needle roller bearing or input shaft.
13. INSPECT 3RD GEAR THRUST CLEARANCE