Output Shaft

E351 MANUAL TRANSAXLE: OUTPUT SHAFT:

INSPECTION

1. INSPECT 1ST GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance:
0.25 to 0.40 mm (0.0098 to 0.0157 in.)
If clearance is out of specification, replace the 1st gear thrust washer, 1st gear or transmission clutch hub No.1.
2. INSPECT 2ND GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 2nd 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.1, 2nd gear or 3rd driven gear.
3. INSPECT 1ST GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 1st gear radial clearance.
Standard clearance:
mm (in.)

If clearance is out of specification, replace the 1st gear and 1st gear needle roller bearing.
4. INSPECT 2ND GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 2nd gear radial clearance.
Standard clearance:
mm (in.)

If clearance is out of specification, replace the 2nd gear and 2nd gear needle roller bearing.
5. INSPECT OUTPUT SHAFT

(a) Using a V-block and a 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 output shaft journal surface.
Outside diameter:
mm (in.)

If the outside diameter is less than the minimum, replace the input shaft.
6. INSPECT 2ND GEAR

(a) Using a cylinder gauge, measure the inside diameter of the 2nd gear.
Inside diameter:
mm (in.)

If the inside diameter exceeds the maximum, replace the 2nd gear.
7. INSPECT 1ST GEAR

(a) Using a cylinder gauge, measure the inside diameter of the 1st gear.
Inside diameter:
mm (in.)

If the inside diameter exceeds the maximum, replace the 1st gear.
8. INSPECT SYNCHRONIZER RING SET NO.2

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

(b) Check the clearance between the synchronizer ring No.2 and 2nd gear while pushing the 2nd gear against the synchronizer ring No.2.
Standard clearance:
0.70 to 1.45 mm (0.0276 to 0.0571 in.)
If clearance is out of specification, replace the synchronizer ring set No.2 with a new one.
9. INSPECT SYNCHRONIZER RING SET NO.1

(a) Coat the 1st gear cone with gear oil. Turn the synchronizer ring set No.1 in one direction while pushing it against the 1st gear cone. Check that the ring locks.
If the synchronizer ring set No.1 does not lock, replace the synchronizer ring set No.1 with a new one.

(b) Check the clearance between the synchronizer ring set No.1 and 1st gear while pushing the 1st gear against the cone of the synchronizer ring set No.1.
Standard clearance:
0.70 to 1.45 mm (0.0276 to 0.0571 in.)
If clearance is out of specification, replace the synchronizer ring set No.1 with a new one.
10. INSPECT REVERSE GEAR

(a) Using vernier calipers, measure the width of the reverse gear groove and thickness of the claw part on the gear shift fork No.1, and calculate the clearance.
Standard clearance:
0.15 to 0.35 mm (0.0059 to 0.0138 in.) {A - B}
If clearance is out of specification, replace the reverse gear and gear shift fork No.1 with new ones.
11. INSPECT TRANSMISSION CLUTCH HUB NO.1

(a) Check the sliding condition between the transmission clutch hub No.1 and the reverse gear.
(b) Check the tip of the spline gear on the sleeve of the reverse gear for wear.
If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.
12. INSPECT 2ND GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 2nd gear radial clearance.
Standard clearance:
mm (in.)

If clearance is out of specification, replace the 2nd gear and 2nd gear needle roller bearing.
13. INSPECT 1ST GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 1st gear radial clearance.
Standard clearance:
mm (in.)

If clearance is out of specification, replace the 1st gear and 1st gear needle roller bearing.
14. INSPECT 2ND GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance:
0.25 to 0.40 mm (0.0098 in. to 0.0157 in.)
If clearance is out of specification, replace the 1st gear thrust washer, 1st gear or transmission clutch hub No.1.