Inspection of Output Shaft Assembly

1. INSPECT EACH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of each gear.

Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Maximum clearance: 0.30 mm (0.0118 in.)




2. INSPECT EACH GEAR OIL CLEARANCE
Using a dial indicator, measure the oil clearance of each gear.

Standard clearance:
1st and 2nd gear 0.009 - 0.060 mm (0.0004 - 0.0024 in.)
3rd gear 0.060 - 0.103 mm (0.0024 - 0.0041 in.)

Maximum clearance:
1st and 2nd gear 0.15 mm (0.0059 in.)
3rd gear 0.20 mm (0.0079 in.)

If the clearance exceeds the maximum, replace the gear, shaft or needle roller bearing.
3. INSPECT SYNCHRONIZER RINGS




a. Check for wear or damage.
b. Turn the ring and push it in to check the braking action.




c. Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end.

Standard clearance: 0.7 - 1.7 mm (0.028 - 0.067 in.)
Minimum clearance: 0.5 mm (0.020 in.)

If the clearance is less than the minimum, replace the synchronizer ring.




4. INSPECT CLEARANCE OF SHIFT FORKS AND HUB SLEEVES
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Maximum clearance: 1.0 mm (0.039 in.)

If the clearance exceeds the maximum, replace the shift fork or hub sleeve.
5. INSPECT OUTPUT SHAFT AND INNER RACE




a. Using vernier calipers, measure the output shaft flange thickness.

Minimum thickness: 5.60 mm (0.2205 in.)

If the thickness exceeds the minimum, replace the output shaft.




b. Using vernier calipers, measure the inner race flange thickness.

Minimum thickness: 4.76 mm (0.1874 in.)

If the thickness exceeds the minimum, replace the inner race.




c. Using a micrometer, measure the outer diameter of the output shaft journal.

Minimum diameter:
2nd gear 42.84 mm (1.6866 in.)
3rd gear 37.80 mm (1.4882 in.)

If the outer diameter exceeds the minimum, replace the output shaft.




d. Using a micrometer, measure the outer diameter of the inner race.

Minimum diameter: 42.85 mm (1.6870 in.)

If the outer diameter exceeds the minimum, replace the inner race.




e. Using a dial indicator, check the shaft runout.

Maximum runout: 0.06 mm (0.0024 in.)

If the runout exceeds the maximum, replace the output shaft.