Inspection

SHIFT CONTROL COMPONENTS
- Check contact and sliding surfaces of fork rods for wear, scratches, projections and other damage.








GEARS AND SHAFTS
- Check shafts for cracks, wear and bending.
- Check gears for excessive wear, chips and cracks.





SYNCHRONIZERS
- Check spline portion of coupling sleeves, synchronizer hubs and gears for wear, chips and cracks.
- Check baulk rings for cracks and deformation.
- Check shifting inserts for wear and deformation.
- Check insert spread springs for deformation.








- Measure baulk ring wear.
Measure clearance between baulk ring and gear. Refer to the illustration for clearance between baulk ring and gear.
- If the clearance is less than the wear limit, replace baulk ring.








- Measure 2nd baulk ring wear.
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk rings against synchronizer cone as far as possible, measure dimensions "A" and "B".
Standard:
Inner "A": 0.7 - 0.9 mm (0.028 - 0.035 inch)
Outer "B": 0.6 - 1.1 mm (0.024 - 0.043 inch)
Wear limit: 0.2 mm (0.008 inch)
c. If dimension "A" or "B" is less than the wear limit, replace baulk ring.





BEARINGS
- Make sure all bearings roll freely and are free from noise, cracks, pitting or wear.