A) Using a micrometer, measure the thickness of the edges of the output shaft.
- Minimum thickness - 4.70 mm
b) Using a micrometer, measure the outside diameter of the output shaft journals.
Minimum Diameter:
- A - 38.860 mm
- B - 46.860 mm
- C - 37.860 mm
V) Using a digital indicator, check the output shaft runout.
- Maximum runout - 0.06 mm
2. Using a micrometer, measure the thickness of the intermediate shaft.
- Minimum diameter - 27.860 mm
3. Check the oil wedge of each gear.
Using a digital indicator, measure the oil wedge between gear and shaft with roller bearing installed.
- Nominal clearance - 0.015 - 0.068 mm
- Maximum clearance - 0.16 mm
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 - 0.8 -1.6 mm
- Minimum clearance - 0.6 mm
5. Using a feeler gauge, measure the clearance between the shift forks and the synchronizer clutches.
- Maximum clearance - 1.0 mm
If the clearance 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.
- Seal installation depth: 11.2- 12.2 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.
- Pressing depth - 25 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 21 mm tool socket and a hammer, drive in a new oil seal.
12. If necessary, replace the extension housing oil seal.
Using the special tool, remove and install a new oil seal.