Cleaning & Inspection
- Wash all parts in cleaning solvent, except sealed bearings, "O" rings and seals. Use scraper or brush for heavy deposits. Rotate bearings by hand in cleaning solvent. Dry all parts with compressed air. Hold bearings while drying to prevent bearing from spinning. DO NOT spin dry bearings. Lubricate clean bearings with multi-purpose grease and wrap in lint-free cloth until ready to install.
- Check clutch hub assembly for worn or damaged splines, synchronizer key groove or shift fork groove. Check for smooth operation as synchronizer hub sleeve is manually engaged and disengaged with synchronizer hub.
- Using a feeler gauge, check for excessive clearance between synchronizer hub sleeve and shift fork. See Fig 1
. See CLUTCH HUB SLEEVE-TO-SHIFT FORK CLEARANCE
. Replace as necessary.CLUTCH HUB SLEEVE-TO-SHIFT FORK CLEARANCE
Application (1) Clearance In. (mm) 1st-2nd .034 (.86) 3rd-4th .039 (1.00) 5th-Reverse .049 (1.25) (1) Maximum clearance. Standard clearance is not available from manufacturer. - Before disassembly, measure differential pinion and side gear backlash. Install left and right axle shafts. Support axle shafts on "V" blocks. Using a dial indicator with magnetic base and flex arm, measure backlash of both pinion gears. Backlash should be 0-.004" (0-.10 mm). If measurement is not within limits, replace differential assembly. See Fig 2 .
- Mount output shaft in a lathe or "V" block. Measure runout at point shown. See Fig 3 . Maximum allowable runout is .0006" (.015 mm).
- Measure diameter of output shaft at point where gear is installed. Measure inside diameter of gear. Subtract shaft diameter from inside gear diameter. Difference between 2 measurements is oil clearance. Standard clearance is .001-.003" (.03-.08 mm). See Fig 4 .
- Inspect input shaft gear teeth for wear or damage. Inspect shaft for heat discoloring or gear or bearing surface damage. Measure input shaft runout by mounting input shaft in lathe or "V" blocks. Measure runout at 3rd gear installation point. Maximum allowable runout is .002" (.05 mm).
- Check reverse idler gear. Install lever end into sleeve in operating position. Using a feeler gauge, check clearance between lever and sleeve shoulder. Standard clearance is .004-.013" (.10-.32 mm). Replace lever or sleeve if clearance is greater than .015" (.37 mm). 9) Inspect synchronizer ring for damaged or worn teeth. Check for smooth engagement with gear. Use a feeler gauge to measure synchronizer ring clearance. See Fig 5 . Press synchronizer ring uniformly against gear and measure around circumference. Standard clearance is .044-.074" (1.12-1.88 mm). Minimum allowable clearance is .031" (.80 mm).