Inspection

Check the following parts and replace if necessary.

1st, 2nd, 3rd, 4th, and 5th gears
1. Worn or damaged synchronizer cone.
2. Worn or damaged hub sleeve coupling.
3. Worn or damaged teeth.
4. Worn or damaged inner surface or end surface of gears.

Synchronizer Ring




1. Engagement with gear
2. Worn or damaged teeth
3. Worn or damaged tapered surface
4. Clearance from side of gear

Clearance: 1.5 mm (0.059 in)
Minimum: 0.8 mm (0.031 in)

NOTE
a. Press the synchronizer ring uniformly against the gear and measure around the circumference.
b. If the clearance is less than specified, replace the synchronizer ring or gear.

Clutch Hub




1. Worn or damaged splines.
2. Worn or damaged synchronizer key groove.
3. Worn end surface.
4. Operation of the hub sleeve when it is installed.

Primary Shaft Gear and Secondary Shaft Gear




1. Worn or damaged gear contact surface.
2. Worn or damaged splines.
3. Worn teeth.
4. Clogged oil passage.
5. Shaft gears' run-out.

Primary shaft gear runout: 0.05 mm (0.002 in) max.




Secondary shaft gear runout: 0.015 mm (0.0006 in) max.

NOTE: If the shaft gear is replaced, adjust the bearing preload.

Oil Clearance:

6. Oil clearance between shaft gears and gears.

Clutch Hub Sleeve

Clearance:

1. Worn or damaged hub splines.
2. Worn or damaged sleeve fork groove.
3. Clearance between sleeve and shift fork.

Synchronizer Key and Spring




1. Worn key.
2. Bent spring.

Reverse Idle Gear




1. Worn or damaged bushing.
2. Worn or damaged teeth.
3. Worn or damaged reverse shift lever coupling groove.
4. Clearance between sleeve and reverse shift lever.

Standard: 0.095-0.318 mm (0.004-0.013 in)
Maximum: 0.5 mm (0.020 in)

Clutch Housing, Transaxle Case, Rear Cover, and Differential Gear Case




Cracks or damage.

CAUTION: If the clutch housing, transaxle case, or differential gear case is replaced, adjust the bearing preload of the shaft gears and the preload of the differential side bearings.

Bearing




1. Roughness or noise while turning
2. Worn or damaged outer race or rollers

CAUTION
a. Replace the bearing, the outer race, and the inner race as a unit.
b. If the bearing is replaced, adjust the preload.

Speedometer Driven Gear Assembly




Worn or damaged teeth.

Ring Gear Speedometer Drive Gear
Worn or damaged teeth.