Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Inspection [06/2015 - ]: Procedure
- INSPECT 1ST GEAR THRUST CLEARANCE
- INSPECT 2ND GEAR THRUST CLEARANCE
- INSPECT 1ST GEAR RADIAL CLEARANCE
- INSPECT 2ND GEAR RADIAL CLEARANCE
- INSPECT OUTPUT SHAFT
- Using a dial indicator and 2 V-blocks, check the output shaft runout.
Maximum Runout
0.03 mm (0.00118 in.)
If the runout exceeds the maximum, replace the output shaft.
- Using a micrometer, measure the outer diameter of the output shaft journal surface at the locations indicated.
Standard Outer Diameter
Part (A)
30.002 to 30.017 mm (1.18118 to 1.18177 in.)
Part (B)
37.990 to 38.000 mm (1.49567 to 1.49606 in.)
Part (C)
40.680 to 40.700 mm (1.60157 to 1.60236 in.)
Part (D)
40.790 to 40.800 mm (1.6059 to 1.6063 in.)
Part (E)
28.002 to 28.017 mm (1.10244 to 1.10303 in.)
Minimum Outer Diameter
Part (A)
30.002 mm (1.18118 in.)
Part (B)
37.990 mm (1.49567 in.)
Part (C)
40.680 mm (1.60157 in.)
Part (D)
40.790 mm (1.6059 in.)
Part (E)
28.002 mm (1.10244 in.)
If the outer diameter of any location is less than the minimum, replace the output shaft.
- Using a dial indicator and 2 V-blocks, check the output shaft runout.
- INSPECT 1ST GEAR
- INSPECT 2ND GEAR
- INSPECT 1ST GEAR BUSHING
- Using a micrometer, measure the outer diameter of the 1st gear bushing.
Standard Outer Diameter
47.89 to 47.90 mm (1.88543 to 1.88582 in.)
Minimum Outer Diameter
47.89 mm (1.88543 in.)
If the outer diameter is less than the minimum, replace the 1st gear bushing.
- Using a cylinder gauge, measure the inside diameter of the 1st gear bushing.
Standard Inside Diameter
40.805 to 40.820 mm (1.60649 to 1.60708 in.)
Maximum Inside Diameter
40.820 mm (1.60708 in.)
If the inside diameter exceeds the maximum, replace the 1st gear bushing.
- Using a micrometer, measure the outer diameter of the 1st gear bushing.
- INSPECT INNER 2ND GEAR BEARING RACE
- Using a micrometer, measure the outer diameter of the inner 2nd gear bearing race.
Standard Outer Diameter
47.89 to 47.90 mm (1.88543 to 1.88582 in.)
Minimum Outer Diameter
47.89 mm (1.88543 in.)
If the outer diameter is less than the minimum, replace the inner 2nd gear bearing race.
- Using a cylinder gauge, measure the inside diameter of the inner 2nd gear bearing race.
Standard Inside Diameter
38.005 to 38.020 mm (1.49626 to 1.49685 in.)
Maximum Inside Diameter
38.020 mm (1.49685 in.)
If the inside diameter exceeds the maximum, replace the inner 2nd gear bearing race.
- Using a micrometer, measure the outer diameter of the inner 2nd gear bearing race.
- INSPECT NO. 1 SYNCHRONIZER RING SET (for 1st Gear)
- Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.
- Install the inner ring to the 1st gear.
*a Outer Ring *b Middle Ring *c Inner Ring - Install the middle ring to the 1st gear.
- Install the outer ring to the 1st gear.
- Check for wear and damage.
*a Lock - Turn the No. 1 synchronizer ring set (inner ring, middle ring and outer ring) in one direction while pushing it against the 1st gear cone.
- Check that the No. 1 synchronizer ring set (inner ring, middle ring and outer ring) locks.
If the No. 1 synchronizer ring set (inner ring, middle ring and outer ring) does not lock, replace the No. 1 synchronizer ring set (inner ring, middle ring and outer ring).
- Using a feeler gauge, measure the clearance between the No. 1 synchronizer ring set (inner ring, middle ring and outer ring) and 1st gear spline end.
Standard Clearance
0.915 to 1.855 mm (0.0360 to 0.0730 in.)
Minimum Clearance
0.915 mm (0.0360 in.)
If the clearance is less than the minimum, replace the No. 1 synchronizer ring set (inner ring, middle ring and outer ring).
- INSPECT NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)
- Coat the 2nd gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.
- Install the inner ring to the 2nd gear.
*a Outer Ring *b Middle Ring *c Inner Ring - Install the middle ring to the 2nd gear.
- Install the outer ring to the 2nd gear.
- Check for wear and damage.
*a Lock - Turn the No. 1 synchronizer ring set (inner ring, middle ring and outer ring) in one direction while pushing it against the 2nd gear cone.
- Check that the No. 1 synchronizer ring set (inner ring, middle ring and outer ring) locks.
If the No. 1 synchronizer ring set (inner ring, middle ring and outer ring) does not lock, replace the No. 1 synchronizer ring set (inner ring, middle ring and outer ring).
- Using a feeler gauge, measure the clearance between the No. 1 synchronizer ring set (inner ring, middle ring and outer ring) and 2nd gear spline end.
Standard Clearance
0.92 to 1.86 mm (0.0362 to 0.0732 in.)
Minimum Clearance
0.92 mm (0.0362 in.)
If the clearance is less than the minimum, replace the No. 1 synchronizer ring set (inner ring, middle ring and outer ring).
- INSPECT REVERSE GEAR
- Using a vernier caliper, measure the width of the reverse gear groove (A) and thickness of the claw part on the No. 1 gear shift fork shaft assembly (B), and calculate the clearance.
*a Clearance Standard Clearance (A) - (B)
0.1 to 0.5 mm (0.00394 to 0.0197 in.)
If the clearance is out of specification, replace the reverse gear and No. 1 gear shift fork shaft assembly.
- Using a vernier caliper, measure the width of the reverse gear groove (A) and thickness of the claw part on the No. 1 gear shift fork shaft assembly (B), and calculate the clearance.
- INSPECT NO. 1 TRANSMISSION CLUTCH HUB
NO RELATED
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.