Output Shaft

E351 MANUAL TRANSMISSION / 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 (0.00984 to 0.0157 in.)
If the clearance is out of specification, replace the 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 (0.00394 to 0.0138 in.)
If the clearance is not as specified, 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:

If the 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:

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

(a) Using V-blocks and a dial indicator, inspect the shaft for runout.
Maximum runout:
0.03 mm (0.00118 in.)
If runout exceeds the maximum, replace the output shaft.

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

If the outside diameter is less than the minimum, replace the output 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.

(b) Check for wear and damage.
(c) Turn the synchronizer ring set in one direction while pushing it against the 2nd gear cone.
(d) Check that the ring locks.
If the synchronizer ring set does not lock, replace the synchronizer ring set.

(e) Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.
Standard clearance:
0.70 to 1.45 mm (0.0276 to 0.0571 in.)
If the clearance is less than the minimum, replace the synchronizer ring set.
9. INSPECT NO. 1 SYNCHRONIZER RING SET
(a) Coat the 1st gear cone with gear oil.

(b) Check for wear and damage.
(c) Turn the synchronizer ring set in one direction while pushing it against the 1st gear cone.
(d) Check that the ring set locks.
If the synchronizer ring set does not lock, replace the synchronizer ring set.

(a) Using a vernier caliper, 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 (0.00591 to 0.0138 in.) {A - B}
If the clearance is not as specified, 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.