Service Manual

Transaxle Inspection
1. Thoroughly clean and dry all parts.
2. Use emery cloth to remove nicks and burrs from all
parts.
3. Inspect synchronizer ring:
A. Inspect the chamfer for excessive wear or dam-
age.
B. Inspect inner tapered area for excessive wear or
damage.
C. Measure the clearance between synchronizer
Figure 70
ring and synchro gear in three equally spaced
points. If clearance is less than 0.5 mm (.0195 in.)
replace the synchronizer ring.
4. Inspect synchro gears:
A. Inspect the cone surface for roughness, material
transfer (brass color material) or damage.
B. Inspect the spline chamfer for excessive chip-
ping or damage.
C. Inspect I.D. of synchro gear for excessive wear
or
scoring. If synchro gears have the following I.D.,
replace the synchro gear.
Figure 71
SHAFT
BEARING
(GEAR CASE)
BEARING
41T GEAR
FRONT DRIVE
(CENTER PLATE)
22T, 25T, 40T I.D. exceeds 26.08 mm (1.027 in.)
49T I.D. exceeds 29.08 mm (1.145 in.)
5. On 4WD units, inspect 41T gear and front drive shaft
(Fig. 70):
A. Inspect gear teeth for roughness, material trans-
fer (brass color material) or damage.
B. Inspect spline chamfer for excessive chipping or
damage.
C. Inspect I.D. of gear for excessive wear or scor-
ing. Gear should fit snuggly on shaft.
Drive Train
Workman 3000/4000 Series Page 6 – 33
Rev. B
Drive Train