Note: The synchronizer sleeve and hub must be replaced as an assembly.
1. Using a bearing inner race holding chuck, press the race onto the secondary shaft.
2. Measure the gap between the 2nd and 3rd gears.
- Standard: 0.06-0.21mm
- Limit: 0.3 mm
3. If the clearance is greater than the specified limit, measure the thickness of the 3rd gear.
- Standard; 34.92-34.97 mm
- Limit: 34.8 mm
If the thickness of the 3rd gear is less than the specified limit, replace the 3rd gear with a new one.
If the thickness of the 3rd gear gear is within the norm, replace it with a new 3rd/4th gear synchronizer hub.
4. Measure the clearance between the 4th gear and the spacer sleeve (upper figure in the center column).
- Standard: 0.06-0.21mm
- Limit: 0.3 mm
5. If the clearance is greater than the specified limit, measure the distance (A) on the spacer sleeve.
- Standard: 26.03-26.08 mm
- Limit: 26.01 mm
6. If the distance (A) is less than the specified limit, replace the spacer sleeve with a new one.
If the distance (A) is within the standard, measure the thickness of the 4th gear.
- Standard: 31.42-31.47 mm
- Limit: 31.3 mm
If the thickness of the 4th gear is less than the specified limit, replace the 4th gear with a new one.
If the 4th gear gear thickness is within the normal range, replace it with a new 3rd/4th gear synchronizer hub.
7. Measure the clearance between the spacer sleeve and the 5th gear.
- Standard: 0.06-0.21mm
- Limit: 0.3 mm
8. If the clearance is greater than the specified limit, measure the distance (B) on the spacer sleeve.
- Standard: 26.03-26.08 mm
- Limit: 26.01 mm
9. If the distance (B) is less than the specified limit, replace the spacer sleeve with a new one.
If the distance (B) is within the standard, measure the thickness of the 5th gear.
- Standard: 30.92-30.97 mm
- Limit: 30.8 mm
If the thickness of the 5th gear is less than the specified limit, replace the 5th gear with a new one.
If the 5th gear thickness is within the normal range, replace with a new 5th gear synchronizer hub.