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Front Output Assembly: Inspection

  1. Inspect front output shaft. Measure the outer diameter of the front output shaft journal surface. See FRONT OUTPUT SHAFT JOURNAL DIAMETER  table.
    FRONT OUTPUT SHAFT JOURNAL DIAMETER

    Clearance Specification In. (mm)
    Minimum 1.4539 (36.930)
  2. Check oil clearance of driven sprocket. Using a dial indicator, measure the oil clearance between the sprocket and shaft with the needle roller bearing installed. See DRIVEN SPROCKET CLEARANCE  table. If the clearance exceeds the limit, replace the driven sprocket, front output shaft or needle roller bearing.
    DRIVEN SPROCKET CLEARANCE

    Clearance Specification In. (mm)
    Standard 0.0004-0.0022 (0.010-0.057)
    Maximum 0.0059 (0.15)
  3. Inspect synchronizer ring. Turn the ring and push it in to check the braking action. Measure the clearance between the synchronizer ring back and the sprocket spline end. See SYNCHRONIZER RING BACK TO SPROCKET SPLINE END CLEARANCE  table. If the clearance is less than the limit, replace the synchronizer ring.
    SYNCHRONIZER RING BACK TO SPROCKET SPLINE END CLEARANCE

    Clearance Specification In. (mm)
    Standard 0043-0.075 (1.1-1.9)
    Minimum 0.031 (0.8)
  4. Measure clearance of No. 1 shift fork and No. 2 hub sleeve. Using a feeler gauge, measure the clearance between No. 1 shift fork and No. 2 hub sleeve. See NO. 1 SHIFT FORK TO NO. 2 HUB SLEEVE CLEARANCE  table. If the clearance exceeds the limit, replace the shift fork or hub sleeve.
    NO. 1 SHIFT FORK TO NO. 2 HUB SLEEVE CLEARANCE

    Clearance Specification In. (mm)
    Maximum 0.039 (1.0)
  5. If necessary, replace front output shaft rear bearing. Using SST (09950-00020) and a socket wrench, press out the bearing. Using SST (09506-30012) and a press, install a new bearing.
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