EC60 MANUAL TRANSMISSION / TRANSAXLE  OUTPUT SHAFT  INSPECTION  


PROCEDURE

Hide 1.INSPECT 1ST GEAR THRUST CLEARANCE

a.
C194350

Using a dial indicator, measure the 1st gear thrust clearance.

Standard Clearance:

0.20 to 0.38 mm (0.00787 to 0.0150 in.)


Maximum Clearance:

0.38 mm (0.0150 in.)


If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 1st gear bushing or 1st gear.


Hide 2.INSPECT 2ND GEAR THRUST CLEARANCE

a.
C194351

Using a dial indicator, measure the 2nd gear thrust clearance.

Standard Clearance:

0.15 to 0.33 mm (0.00591 to 0.0130 in.)


Maximum Clearance:

0.33 mm (0.0130 in.)


If the clearance exceeds the maximum, replace the inner 2nd gear bearing race, No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.


Hide 3.INSPECT 1ST GEAR RADIAL CLEARANCE

a.
C194352

Using a dial indicator, measure the 1st gear radial clearance.

Standard Clearance:

0.009 to 0.047 mm (0.000354 to 0.00185 in.)


Maximum Clearance:

0.047 mm (0.00185 in.)


If the clearance exceeds the maximum, replace the 1st gear, 1st gear needle roller bearing or output shaft.


Hide 4.INSPECT 2ND GEAR RADIAL CLEARANCE

a.
C194353

Using a dial indicator, measure the 2nd gear radial clearance.

Standard Clearance:

0.009 to 0.047 mm (0.000354 to 0.00185 in.)


Maximum Clearance:

0.047 mm (0.00185 in.)


If the clearance exceeds the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output shaft.


Hide 33321 5.INSPECT OUTPUT SHAFT

a.
C304892

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.


b.
C294821
0.219,3.271 0.542,3.521 0.323,0.25 10 false A 2.323,3.188 2.646,3.438 0.323,0.25 10 false C 1.844,3.188 2.167,3.438 0.323,0.25 10 false B 2,4.385 2.323,4.635 0.323,0.25 10 false B 2.438,4.385 2.76,4.635 0.323,0.25 10 false D 2.99,3.24 3.313,3.49 0.323,0.25 10 false E

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 (1.1812 to 1.1818 in.)

Part (B):

37.990 to 38.000 mm (1.4957 to 1.4961 in.)

Part (C):

40.790 to 40.800 mm (1.6059 to 1.6063 in.)

Part (D):

40.790 to 40.800 mm (1.6059 to 1.6063 in.)

Part (E):

28.002 to 28.017 mm (1.1024 to 1.1030 in.)


Minimum Outer Diameter:
Part (A):

30.002 mm (1.1812 in.)

Part (B):

37.990 mm (1.4957 in.)

Part (C):

40.790 mm (1.6059 in.)

Part (D):

40.790 mm (1.6059 in.)

Part (E):

28.002 mm (1.1024 in.)


If the outer diameter of any location is less than the minimum, replace the output shaft.


Hide 33335 6.INSPECT 1ST GEAR

a.
C194372

Using a cylinder gauge, measure the inside diameter of the 1st gear.

Standard Inside Diameter:

52.909 to 52.925 mm (2.0830 to 2.0836 in.)


Maximum Inside Diameter:

52.925 mm (2.0836 in.)


If the inside diameter exceeds the maximum, replace the 1st gear.


Hide 33332 7.INSPECT 2ND GEAR

a.
C194373

Using a cylinder gauge, measure the inside diameter of the 2nd gear.

Standard Inside Diameter:

52.909 to 52.925 mm (2.0830 to 2.0836 in.)


Maximum Inside Diameter:

52.925 mm (2.0836 in.)


If the inside diameter exceeds the maximum, replace the 2nd gear.


Hide 33345 8.INSPECT 1ST GEAR BUSHING

a.
C194374

Using a micrometer, measure the outer diameter of the 1st gear bushing.

Standard Outer Diameter:

47.89 to 47.90 mm (1.8854 to 1.8858 in.)


Minimum Outer Diameter:

47.89 mm (1.8854 in.)


If the outer diameter is less than the minimum, replace the 1st gear bushing.


b.
C194376

Using a cylinder gauge, measure the inside diameter of the 1st gear bushing.

Standard Inside Diameter:

40.805 to 40.820 mm (1.6065 to 1.6071 in.)


Maximum Inside Diameter:

40.820 mm (1.6071 in.)


If the inside diameter exceeds the maximum, replace the 1st gear bushing.


Hide 33356A 9.INSPECT INNER 2ND GEAR BEARING RACE

a.
C194375

Using a micrometer, measure the outer diameter of the inner 2nd gear bearing race.

Standard Outer Diameter:

47.89 to 47.90 mm (1.8854 to 1.8858 in.)


Minimum Outer Diameter:

47.89 mm (1.8854 in.)


If the outer diameter is less than the minimum, replace the inner 2nd gear bearing race.


b.
C194377

Using a cylinder gauge, measure the inside diameter of the inner 2nd gear bearing race.

Standard Inside Diameter:

38.005 to 38.020 mm (1.4963 to 1.4968 in.)


Maximum Inside Diameter:

38.020 mm (1.4968 in.)


If the inside diameter exceeds the maximum, replace the inner 2nd gear bearing race.


Hide 33037B 10.INSPECT NO. 1 SYNCHRONIZER RING SET (for 1st Gear)

a.

Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.


b.
C195453
1.406,1.917 0.99,1.917 false 1.354,1.271 0.99,1.271 false 1.333,0.583 1,0.583 false 0.802,1.833 1,2.063 0.198,0.229 10 *c 0.813,1.167 1.052,1.417 0.24,0.25 10 *b 0.813,0.5 1,0.729 0.188,0.229 10 *a
*a Outer Ring
*b Middle Ring
*c Inner Ring


Install the inner ring to the 1st gear.


c.

Install the middle ring to the 1st gear.


d.

Install the outer ring to the 1st gear.


e.
C204836
1.615,0.219 2.375,0.604 0.76,0.385 10 *a
*a Locks


Check for wear and damage.


f.

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.


g.

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).


h.
C194379

Using a feeler gauge, measure the clearance between the No. 1 synchronizer ring set (inner ring, middle ring and outer ring) and the 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).


Hide 33037B 11.INSPECT NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)

a.

Coat the 2nd gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.


b.
C195454
0.74,0.573 1.208,0.573 false 0.771,1.344 1.24,1.344 false 0.823,2.063 1.292,2.063 false 0.531,0.5 0.844,0.656 0.313,0.156 10 *a 0.563,1.26 0.875,1.417 0.313,0.156 10 *b 0.594,1.979 0.906,2.135 0.313,0.156 10 *c
*a Outer Ring
*b Middle Ring
*c Inner Ring


Install the inner ring to the 2nd gear.


c.

Install the middle ring to the 2nd gear.


d.

Install the outer ring to the 2nd gear.


e.
C204837
1.729,0.354 2.052,0.583 0.323,0.229 10 *a
*a Locks


Check for wear and damage.


f.

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.


g.

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).


h.
C194381

Using a feeler gauge, measure the clearance between the No. 1 synchronizer ring set (inner ring, middle ring and outer ring) and the 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).


Hide 33331 12.INSPECT REVERSE GEAR

a.
C194382
0.167,1.583 0.313,1.792 0.146,0.208 10 B 2.208,3.115 2.354,3.323 0.146,0.208 10 A 0.344,4.344 1.656,4.563 1.313,0.219 10 *a = A - B
*a Clearance


Using a vernier caliper, measure the width of the reverse gear groove (A) and the thickness of the claw part on the No. 1 gear shift fork shaft assembly (B), and calculate the 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.


Hide 33361 13.INSPECT NO. 1 TRANSMISSION CLUTCH HUB

a.
C194383

Check that the No. 1 transmission clutch hub and reverse gear slide smoothly.


b.

Check that the edges of the reverse gear splines are not worn down.