EC60 MANUAL TRANSMISSION / TRANSAXLE OUTPUT SHAFT INSPECTION
PROCEDURE
1.INSPECT 1ST GEAR THRUST CLEARANCE
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.
2.INSPECT 2ND GEAR THRUST CLEARANCE
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.
3.INSPECT 1ST GEAR RADIAL CLEARANCE
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.
4.INSPECT 2ND GEAR RADIAL CLEARANCE
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.
33321 5.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 (1.1812 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.
33335 6.INSPECT 1ST GEAR
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.
33332 7.INSPECT 2ND GEAR
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.
33345 8.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 (1.8854 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.
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.
33356A 9.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 (1.8854 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.
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.
33037B 10.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.
*a | Outer Ring |
*b | Middle Ring |
*c | Inner Ring |
Install the inner ring to the 1st gear.
Install the middle ring to the 1st gear.
Install the outer ring to the 1st gear.
*a | Locks |
Check for wear and damage.
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 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).
33037B 11.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.
*a | Outer Ring |
*b | Middle Ring |
*c | Inner Ring |
Install the inner ring to the 2nd gear.
Install the middle ring to the 2nd gear.
Install the outer ring to the 2nd gear.
*a | Locks |
Check for wear and damage.
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 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).
33331 12.INSPECT REVERSE GEAR
*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.
33361 13.INSPECT NO. 1 TRANSMISSION CLUTCH HUB
Check that the No. 1 transmission clutch hub and reverse gear slide smoothly.
Check that the edges of the reverse gear splines are not worn down.