Input Shaft Inspection

Input Shaft Inspection
^ Check clearance a between synchronizer ring (2) and gear (1), key slot width b in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.





^ Measure width of high speed gear shift fork end a and groove width of high speed synchronizer sleeve b, 5th & reverse gear shift fork end a and groove width of 5th speed synchronizer sleeve b and then calculate clearance c as follows:
Clearance "c" = "b" - "a"
If clearance exceeds limit, replace fork bush (1) and sleeve.

Clearance "c" between fork and sleeve for high speed and 5th speed
Standard: 0.2 - 0.5 mm (0.008 - 0.020 inch)
Limit: 1.0 mm (0.039 inch)





^ Check diameter of input shaft (1) and needle bush (2) as shown in the figure. If measured value is out of specification, replace input shaft and/or bush.

Input shaft and needle bush specifications (diameter)

Input shaft and needle bush specifications (diameter):

^ Using "V" blocks (1) and dial gauge (2), check runout.
If runout exceeds limit below, replace input shaft (3).





^ Using cylinder gauge (1), check inside diameter of each gear. If its inside diameter exceeds specification, replace it.





^ Check chamfered part of each sleeve for damage and excessive wear, and replace as necessary.
^ Check each synchronizer key and synchronizer spring and replace as necessary.
^ Check spline portions and replace parts if excessive wear is found.