TRANSMISSION
L3540-II, L4240-II, L5040-II, L5240-II, L5740-II , WSM
3-S113
(2) Synchronized Gear
Clearance between Shift Fork and Shifter Groove
1. Measure the width of shift fork.
2. Measure the shifter groove width, and calculate the clearance.
3. If the clearance exceeds the allowable limit, replace them.
9Y1211167TRS0147US0
Checking Contact between Coupling and Shifter
1. Check to see if there is flaw or wear on the spline of the coupling
and shifter, and the key groove on the coupling.
2. Engage the shifter with the coupling, and check that they slide
smoothly.
3. Similarly, check that there is any flaw or wear on the gear
splines.
4. If there is any damage, replace them.
9Y1211167TRS0148US0
Flaw on Synchronizer Key and Spring
1. Check the projection in the center of the synchronizer key for
wear.
2. Check the spring for fatigue or wear on the area where the
spring contacts with the keys.
3. If there is any damage, replace them.
9Y1211167TRS0149US0
Side Clearance between Synchronizer Ring and Gear
(In Contact)
1. Press the synchronizer ring against the tapered portion of the
gear, and measure the side clearance.
2. Apply thin film of red lead to the tapered portion, press the ring
against it by hand, rub them together a few times, and check the
contact.
3. Check the tooth surface and key grooves of the ring for wear.
4. If the side clearance exceeds the allowable limit or if there is any
damage, replace the synchronizer ring.
9Y1211167TRS0150US0
Clearance between shift
fork and shifter groove
Factory
specifica-
tion
Shuttle
F-R
0.20 to 0.45 mm
0.0079 to 0.017 in.
Other
0.15 to 0.40 mm
0.0059 to 0.015 in.
Allowable
limit
Shuttle
F-R
0.80 mm
0.03 in.
Other
0.80 mm
0.03 in.
Side clearance Allowable limit
0.35 mm
0.014 in.
Contact condition of
tapered portion
Allowable limit More than 80 %
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