a) Using a caliper, measure the thickness of the secondary shaft edges.
- Minimum thickness - 4.80 mm
b) Using a caliper, measure the thickness of the edges of the inner bearing ring.
- Minimum thickness - 3.99 mm
c) Using a micrometer, measure the outside diameter of the secondary shaft journals.
Minimum diameter:
- 2nd gear - 37.984 mm
- 3rd gear - 34.984 mm
d) Using a micrometer, measure the outside diameter of the bearing inner ring.
- Minimum diameter - 38.985 mm
d) Using a digital indicator, check the runout of the secondary shaft.
- Maximum runout - 0.05 mm
2. Check the oil wedge of the first gear.
a) Using a digital indicator, measure the oil wedge between the pinion and the inner ring of the bearing with the needle bearing installed.
- Nominal clearance - 0.009 - 0.032 mm
- Maximum clearance - 0.032 mm
b) If the gap is greater than the maximum, replace the gear, the inner bearing ring and the bearing.
3. Check the oil wedge on the second, third and intermediate fifth gears.
a) Using a digital indicator, measure the oil wedge between the gear and the shaft with the needle bearing installed.
Nominal clearance:
- second and third gears - 0.009 - 0.033 mm
- intermediate gear of the fifth gear - 0.009 - 0.032 mm
Maximum clearance:
- second and third gears - 0.033 mm
- 5th gear intermediate gear - 0.032 mm
b) If the gap is greater than the maximum, replace the gear, the inner bearing ring and the bearing.
4. Check the synchronizer rings.
a) By turning the synchronizer ring, check its friction properties.
b) Measure the gap between the synchronizer ring and the gear.
- Nominal clearance - 1.0 - 2.0 mm
- Minimum clearance - 0.8 mm
5. Using a feeler gauge, measure the gap between the gear shift forks and the synchronizer sleeves.
- Maximum gap - 1.0 mm
If the gap exceeds the maximum, replace the fork.
6. If necessary, replace the input shaft bearing.
a) Using round-nose pliers, remove the retaining ring.
b) Using a press, remove the bearing and install a new bearing.
c) Select a retaining ring to ensure minimum axial play and install it on the shaft.
7. If necessary, replace the front bearing housing oil seal.
a) Using a screwdriver, remove the seal.
b) Using a tool head, press in a new oil seal.
- Seal installation depth: 12.2 - 13.2 mm
8. If necessary, replace the front intermediate shaft bearing.
a) Using round-nose pliers, remove the retaining ring.
b) Using a vice and a tool head, remove the bearing and replace it.
c) Select a retaining ring to ensure minimum axial play and install it on the shaft.
9. If necessary, replace the speedometer drive gear oil seal.
a) Using a special tool, remove the oil seal.
b) Using a tool head, insert a new oil seal.
- Pressing depth - 20 mm
10. If necessary, replace the gear selector lever seal.
a) Using a screwdriver, remove the seal.
b) Using a 14mm socket and hammer, press in the new seal.
11. If necessary, replace the gear shift lever seal.
a) Using a screwdriver, remove the seal.
b) Using a 17mm socket and hammer, press in the new seal.
12. If necessary, replace the oil seal and the extension housing bushing.
a) Using a special tool, remove the oil seal.
b) Heat the extension cord to 80 - 100°C in an oil bath.
c) Using a tool head, remove the bushing and install a new one.
c) Install a new oil seal.
