Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft (B).
2.
Measure the clearance between 2nd gear (C) and 3rd gear (D) with a feeler gauge (E).
If the clearance exceeds the service limit, go to step 3.
If the clearance is within the service limit, go to step 4.
Standard:
0.06?0.21 mm (0.003?0.008 in)
Service Limit:
0.21 mm (0.008 in)
3.
Measure the thickness of 3rd gear.
If the thickness is less than the service limit, replace 3rd gear.
If the thickness is within the service limit, replace the 3rd/4th synchro hub and the 3rd/4th synchro sleeve as a set.
Standard:
27.02?27.07 mm (1.0638?1.0657 in)
Service Limit:
27.02 mm (1.0638 in)
4.
Measure the clearance between 4th gear (A) and the 4th/5th gear distance collar (B) with a dial indicator (C).
If the clearance exceeds the service limit, go to step 5.
If the clearance is within the service limit, go to step 7.
Standard:
0.06?0.19 mm (0.0024?0.0075 in)
Service Limit:
0.19 mm (0.0075 in)
5.
Measure the length of the 4th/5th gear distance collar as shown.
If the length is not within the standard, replace the 4th/5th gear distance collar.
If the length is within the standard, go to step 6.
Standard:
22.53?22.56 mm (0.8870?0.8882 in)
6.
Measure the thickness of 4th gear.
If the thickness is less than the service limit, replace 4th gear.
If the thickness is within the service limit, replace the 3rd/4th synchro hub and the 3rd/4th synchro sleeve as a set.
Standard:
25.52?25.57 mm (1.0047?1.0067 in)
Service Limit:
25.52 mm (1.0047 in)
7.
Measure the clearance between the 4th/5th gear distance collar (A) and 5th gear (B) with a dial indicator (C).
If the clearance exceeds the service limit, go to step 8.
If the clearance is within the service limit, go to step 10.
Standard:
0.06?0.14 mm (0.0024?0.0055 in)
Service Limit:
0.14 mm (0.0055 in)
8.
Measure the length of the 4th/5th gear distance collar as shown.
If the length is not within the standard, replace the 4th/5th gear distance collar.
If the length is within the standard, go to step 9.
Standard:
22.53?22.56 mm (0.8870?0.8882 in)
9.
Measure the thickness of 5th gear.
If the thickness is less than the service limit, replace 5th gear.
If the thickness is within the service limit, replace the 5th/6th synchro hub and the 5th/6th synchro sleeve as a set.
Standard:
22.42?22.47 mm (0.8827?0.8846 in)
Service Limit:
22.42 mm (0.8827 in)
10.
Measure the clearance between 6th gear (A) and the angular ball bearing inner race (B) with a feeler gauge (C). If the clearance exceeds the service limit, go to step 11.
Standard:
0.06?0.16 mm (0.003?0.006 in)
Service Limit:
0.16 mm (0.006 in)
11.
Measure the length of the 6th gear distance collar.
If the length is not within the standard, replace the 6th gear distance collar.
If the length is within the standard, go to step 12.
Standard:
24.03?24.08 mm (0.9461?0.9480 in)
12.
Measure the thickness of 6th gear.
If the thickness is less than the service limit, replace 6th gear.
If the thickness is within the service limit, replace the 5th/6th synchro hub and the 5th/6th synchro sleeve as a set.
of the 4th/5th gear distance collar as shown.
is not within the standard, replace the 4th/5th gear distance collar.
is within the standard, go to step 6.
of the 4th/5th gear distance collar as shown.
is not within the standard, replace the 4th/5th gear distance collar.
is within the standard, go to step 9.