Input Shaft (Km200, Km201, F4M21 & F5M21): Inspection

Inspect input shaft bearing surfaces for wear, seizure and damage. Inspect shaft splines for damage and wear. Assemble needle bearing to shaft and ensure it rotates smoothly without abnormal noise, roughness or play. Inspect bearing cage for deformation.
Inspect synchronizer ring for damaged or broken teeth. Inspect inner surface for damage, wear and broken threads. Force synchronizer ring toward clutch gear and check clearance between gear and synchronizer ring. Replace synchronizer ring if clearance is not at least .02" (.5 mm). See Fig 2 .

Fig 1: Exploded View Of Input Shaft (F5M31 Shown; Other Similar)
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.

Fig 2: Checking Synchronizer-To-Gear Clearance
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
Insert synchronizer hub into sleeve. Ensure they slide smoothly. Ensure sleeve is not damaged or worn at inside front and rear edges. Inspect for wear on gear mating surfaces of hub. Inspect for wear of synchronizer key center protrusion. Inspect spring for weakness, deformation and breakage.
NOTE: Replace synchronizer sleeve and hub as a set.
Inspect synchronizer cone for rough surface, damage and wear. Inspect gear bore and front and rear mating surfaces for damage and wear.