#
MANUAL TRANSMISSION INSPECTION

BHE051117050103

## Drive Gear Inspection

### Thrust clearance inspection

1. Measure the thrust clearance of each gear using a feeler gauge and a dial gauge as shown in the figure.

Thrust clearance

mm {in}

Gear | Thrust clearance
--- | ---
1st | 0.15-0.40 {0.006-0.015}
2nd | 0.10-0.45 {0.004-0.017}
3rd | 0.10-0.35 {0.004-0.013}
4th | 0.10-0.35 {0.004-0.013}
6th | 0.10-0.40 {0.004-0.015}
Reverse | 0.10-0.45 {0.004-0.017}

  • If not within the specification, replace the malfunctioning parts.

### Radial clearance inspection

1. Measure the radial clearance of each gear using a dial gauge.

Radial clearance

mm {in}

Gear | Radial clearance
--- | ---
1st | 0.015-0.066 {0.0006-0.0025}
2nd | 0.015-0.066 {0.0006-0.0025}
3rd | 0.015-0.068 {0.0006-0.0026}
4th | 0.065-0.115 {0.0026-0.0045}
5th (Drive gear) | 0.029-0.072 {0.0012-0.0028}
6th | 0.015-0.068 {0.0006-0.0026}
Reverse | 0.015-0.066 {0.0006-0.0025}

  • If not within the specification, replace the synchronizer ring.

## Reverse Idler Gear and Reverse Idler Shaft Inspection

### Radial clearance inspection

1. Secure the reverse idler gear and reverse idler shaft in a vise, and measure the radial clearance using a dial gauge.

  Radial clearance
  0.040-0.082 mm {0.0016-0.0032 in}

• If not within the specification, replace the reverse idler gear and the reverse idler shaft.

## Synchronizer Ring Inspection

1. Set the synchronizer ring evenly in the gear, and measure the clearance between the synchronizer ring and flank surface of the gear all around the circumference using a feeler gauge.

Clearance

mm {in}

Gear | BP | 13B-MSP
--- | --- | ---
1st, 2nd, 3rd | Inner ring | 0.98-1.62 {0.04-0.06}
Middle ring | 0.68-1.92 {0.03-0.07}
Synchronizer ring | - | 0.88-1.72 {0.04-0.06}
3rd | 0.90-1.70 {0.04-0.06} | -
4th, 5th | 0.80-1.60 {0.04-0.06}
6th, Reverse | 0.88-1.52 {0.04-0.05}

• If not within the specification, replace the synchronizer ring.

## Mainshaft Inspection

1. Hold the mainshaft with the V-blocks and measure the runout using a dial gauge as shown in the figure.

  Maximum runout
  0.03 mm {0.0012 in}

• If it exceeds the maximum specification, replace the mainshaft.

## Countershaft Inspection

1. Hold the countershaft with the V-blocks and measure the runout using a dial gauge as shown in the figure.

  Maximum runout
  0.03 mm {0.0012 in}

• If it exceeds the maximum specification, replace the countershaft.

## Clutch Hub Sleeve and Shift Fork Inspection

1. Measure the shift fork thickness and the groove width of the clutch hub sleeve with a vernier caliper, and calculate the clearance.

  Clearance
  0.15-0.35 mm {0.006-0.013 in}

• If not within the specification, replace the clutch hub sleeve and shift fork.