Output Shaft

E351 MANUAL TRANSAXLE: OUTPUT SHAFT: INSPECTION

INSPECTION

1. INSPECT 1ST GEAR THRUST CLEARANCE





(a) Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance:
0.25 to 0.40 mm (0.0098 to 0.0157 in.)
If clearance is out of specification, replace the 1st gear, thrust washer, 1st gear, or No. 1 transmission clutch hub.
2. INSPECT 2ND GEAR THRUST CLEARANCE





(a) Using a dial indicator, measure the 2nd gear thrust clearance.
Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
If clearance is out of specification, replace the No. 1 transmission clutch hub, 2nd gear, or 3rd driven gear.
3. INSPECT 1ST GEAR RADIAL CLEARANCE





(a) Using a dial indicator, measure the 1st gear radial clearance.
Standard clearance mm (in.):





If clearance is out of specification, replace the 1st gear and 1st gear needle roller bearing.
4. INSPECT 2ND GEAR RADIAL CLEARANCE





(a) Using a dial indicator, measure the 2nd gear radial clearance.
Standard clearance mm (in.):





If clearance is out of specification, replace the 2nd gear and 2nd gear needle roller bearing.
5. INSPECT OUTPUT SHAFT





(a) Using a V-block and a dial indicator, inspect the shaft for runout.
Maximum runout:
0.03 mm (0.0012 in.)
If runout exceeds the maximum, replace the input shaft.





(b) Using a micrometer, measure the outside diameter of the output shaft journal surface.
Outside diameter mm (in.):





If the outside diameter is less than the minimum, replace the input shaft.
6. INSPECT 2ND GEAR





(a) Using a cylinder gauge, measure the inside diameter of the 2nd gear.
Inside diameter:
mm (in.)





If the inside diameter exceeds the maximum, replace the 2nd gear.
7. INSPECT 1ST GEAR





(a) Using a cylinder gauge, measure the inside diameter of the 1st gear.
Inside diameter mm (in.):





If the inside diameter exceeds the maximum, replace the 1st gear.
8. INSPECT NO. 2 SYNCHRONIZER RING SET





(a) Coat the 2nd gear cone with gear oil. Turn the No. 2 synchronizer ring set in one direction while pushing it against the No. 2 synchronizer ring. Check that the ring locks.
If the No. 2 synchronizer ring set does not lock, replace the ring or 2nd gear.





(b) Check the clearance between the No. 2 synchronizer ring and 2nd gear while pushing the 2nd gear against the No. 2 synchronizer ring.
Standard clearance:
0.70 to 1.45 mm (0.0276 to 0.0571 in.)
If clearance is out of specification, replace the No. 2 synchronizer ring set with a new one.
9. INSPECT NO. 1 SYNCHRONIZER RING SET





(a) Coat the 1st gear cone with gear oil. Turn the No. 1 synchronizer ring set in one direction while pushing it against the 1st gear cone. Check that the ring locks.
If the No. 1 synchronizer ring set does not lock, replace the No. 1 synchronizer ring set with a new one.





(b) Check the clearance between the No. 1 synchronizer ring set and 1st gear while pushing the 1st gear against the cone of the No. 1 synchronizer ring set.
Standard clearance:
0.70 to 1.45 mm (0.0276 to 0.0571 in.)
If clearance is out of specification, replace the No. 1 synchronizer ring set with a new one.
10. INSPECT REVERSE GEAR





(a) Using vernier calipers, measure the width of the reverse gear groove and thickness of the claw part on the No. 1 gear shift fork, and calculate the clearance.
Standard clearance:
0.15 to 0.35 mm (0.0059 to 0.0138 in.) {A - B}
If clearance is out of specification, replace the reverse gear and No. 1 gear shift fork with new ones.
11. INSPECT NO. 1 TRANSMISSION CLUTCH HUB





(a) Check the sliding condition between the No. 1 transmission clutch hub and the reverse gear.
(b) Check the tip of the spline gear on the sleeve of the reverse gear for wear.
If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.