INSPECTION

MAINSHAFT

1.Check the outer surface of the mainshaft where the needle bearing is mounted for damage, abnormal wear and seizure (portion "A").
2.Check the splines for damage wear.

SYNCHRONIZER RING

1.Check the clutch gear teeth for damage and breakage.
2.Check the internal surface for damage, wear and broken threads.

3.Force the synchronizer ring toward the clutch gear and check clearance "A." Replace if it is out of specification.
Limit: 0.5 mm

SYNCHRONIZER SLEEVE AND HUB

caution

When replacing, replace the synchronizer hub and sleeve as a set.

1.Combine the synchronizer sleeve and hub and check that they slide smoothly.
2.Check that the sleeve is free from damage at its inside front and rear ends.
3.Check for wear of the hub end surface (in contact with each speed gear).

SYNCHRONIZER OUTER RING/SYNCHRONIZER INNER RING/ SYNCHRONIZER CONE

caution

When any of the outer ring, inner ring or cone has to be replaced, replace them as a set.

1.Check to ensure that the clutch gear tooth surfaces and cone surfaces are not damaged and broken.

2.Install the outer ring, inner ring and cone, press them against the gear, and check clearance "A." If "A" is less than the limit, replace it.
Limit: 0.3 mm

SYNCHRONIZER KEY AND SPRING

1.Check the synchronizer key center protrusion for wear.
2.Check the spring for weakness, deformation and breakage.

SPEED GEAR

1.Check the bevel gear and clutch gear teeth for damage and wear.
2.Check the synchronizer cone for rough surface, damage and wear.
3.Check the gear bore and front and rear ends for damage and wear.