A) Using a vernier caliper, measure the thickness of the edges of the output shaft.
- Minimum thickness - 4.80 mm
b) Using a vernier caliper, measure the lip thickness of the bearing inner race.
- Minimum thickness - 3.99 mm
V) Using a micrometer, measure the outside diameter of the output shaft journals.
Minimum Diameter:
- 2nd gear - 37.984 mm
- 3rd gear - 34.984 mm
G) Using a micrometer, measure the outside diameter of the bearing inner race.
- Minimum diameter - 38.985 mm
d) Using a digital indicator, check the output shaft runout.
- Maximum runout - 0.05 mm
2. Check the first gear oil wedge.
A) Using a digital indicator, measure the oil wedge between the gear and the bearing inner race with the needle bearing installed.
- Nominal clearance - 0.009 - 0.032 mm
- Maximum clearance - 0.032 mm
b) If the clearance is greater than the maximum, replace the gear, the inner race of the bearing 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 gear and shaft with needle bearing installed.
Rated Clearance:
- gears of the second and third gears - 0.009 - 0.033 mm
- 5th gear intermediate gear - 0.009 - 0.032 mm
Max Clearance:
- gears of the second and third gears - 0.033 mm
- 5th idle gear - 0.032 mm
b) If the clearance is greater than the maximum, replace the gear, the inner race of the bearing and the bearing.
4. Check the synchronizer rings.
A) Turning the synchronizer ring, check its frictional properties.
b) Measure the clearance 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 clearance between the shift forks and the synchronizer clutches.
- Maximum clearance - 1.0 mm
If the gap exceeds the maximum, replace the plug.
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.
V) Select the retaining ring for minimum end play and install it on the shaft.
7. If necessary, replace the front bearing housing seal.
A) Remove the seal using a screwdriver.
b) Using a tool head, press in a new oil seal.
- The installation depth of the stuffing box is 12.2 - 13.2 mm
8. If necessary, replace the intermediate shaft front bearing.
A) Remove the retaining ring using pliers.
b) Using a vise and tool head, remove the bearing and replace it.
V) Select the retaining ring for minimum end play and install it on the shaft.
9. If necessary, replace the speedometer driven gear seal.
A) Remove the seal using the special tool.
b) Using a tool head, insert a new oil seal.
- Depth of pressing - 20 mm
10. If necessary, replace an epiploon of the lever of a choice of transfers.
A) Remove the seal using a screwdriver.
b) Using a 14mm tool socket and a hammer, drive in a new oil seal.
11. If necessary, replace an epiploon of the lever of inclusion of transfers.
A) Remove the seal using a screwdriver.
b) Using a 17mm tool socket and a hammer, drive in a new oil seal.
12. If necessary, replace the oil seal and extension housing bushing.
A) Remove the seal using the special tool.
b) Heat the extension to a temperature of 80 - 100°C in an oil bath.
V) Using a tool head, remove the bushing and install a new one.
With) Install a new oil seal.