#
SECONDARY SHAFT COMPONENTS INSPECTION

BME051517301M03

## Secondary Shaft and Gear Inspection

1. Inspect the shaft for damage, abnormal wear, dents, flaking, or bending.

  • If there is any malfunction, replace the shaft.

2. Inspect the gears for damage, abnormal wear, dents, flaking, or bending.

  • If there is any malfunction, replace the gear.

3. Inspect the oil passage for clogging.

  • If there is any malfunction, replace the shaft.

## Synchronizer Ring and Clutch Hub Component Inspection

1. Inspect the clutch hub sleeve, clutch hub, and synchronizer key contact surface for damage and abnormal wear.

  • If there is any malfunction, replace the part where necessary.

2. Verify that the clutch hub sleeve and clutch hub move smoothly.

  • If there is any malfunction, replace parts if necessary.

3. Inspect the synchronizer ring teeth and grooves for damage, abnormal wear, and cracks.

  • If there is any malfunction, replace the synchronizer ring.

4. Inspect the tapered surface for abnormal wear and cracks.

  • If there is any malfunction, replace parts if necessary.

## Synchronizer Ring Clearance Inspection

### Synchronizer component (1st gear)

1. Measure the clearance of synchronizer component outer, middle and inner synchronizer rings.

  • If clearances A and B less than the minimum specification, replace as a set.
  (1) Measure clearance A in two places or more and on opposite sides using a dial gauge, and calculate the average value.
Clearance A

  Standard: 0.60-0.80 mm {0.0236-0.0315 in}
  Minimum: 0.20 mm {0.0079 in}

  (2) Measure clearance B in two places or more and on opposite sides using a feeler gauge, and calculate the average value.
Clearance B

  Standard: 0.60-1.10 mm {0.0236-0.0433 in}
  Minimum: 0.20 mm {0.0079 in}

### Synchronizer component (2nd gear)

1. Inspect clearance of the synchronizer component outer, middle, and inner synchronizer rings.

  • If the clearance A, B and C less than the minimum specification, replace as a set.
  (1) Measure clearance A in two places or more and on opposite sides using a feeler gauge while the synchronizer ring is manually press fit to the taper surface of the clutch gear, and calculate the average value.
Clearance A

  Standard: 0.60-1.20 mm {0.0236-0.0472 in}
  Minimum: 0.30 mm {0.0118 in}

  (2) Measure clearance B in two places or more and on opposite sides with a feeler gauge, and calculate the average value.
Clearance B

  Standard: 0.60-1.10 mm {0.0236-0.0433 in}
  Minimum: 0.20 mm {0.0079 in}

  (3) Measure clearance C in two places or more and on opposite sides with a feeler gauge while the synchronizer ring is manually press fit to the taper surface of the clutch gear, and calculate the average value.
Clearance C

  Standard: 0.70-1.10 mm {0.0276-0.0433 in}
  Minimum: 0.30 mm {0.0118 in}

## Bearing Inspection

1. Inspect the ball and the ball contact surface for damage and abnormal wear.

  • If there is any malfunction, replace the bearing.

2. Verify that the bearing rotates smoothly.

  • If there is any malfunction, replace the bearing.