Dismantled the manual transmission, which was difficult as it hadn't been dismantled before. found that the thread on the bolts had locktight on them and a few of the bolts became slightly rounded. Started using the 12point socket but it didnt have enough hold on the bolt, so used the 6point hexaganal which had a better grip.
Visually inspected all the parts. The tooth count came back good and the side clearances met the specifications from first to fifth gear, reverse gear, reverse idler, final driver gear, final driven gear, differential and speedometer.
For the synchro system and gears, visually inspecting them for cracks, chips and scratches is the first thing that is required. The baulk rings first to fifth gear side clearances were check and all fell within specification. The circlips need replacing as they have corroded and become brittle. Circlips are needed to hold the components in place.
The spines have little wear and the teeth are in good condition with no chips, scratches or cracks. The housing has a small amount of scatches but will not effect the way it will operate. The breather, seals, threaded holes and bolts are all in good condition and not needed to be replaced.
The gear Ratio formula is Driven / Driver =
First gear: 38/12=3.16
Second gear: 40/21=1.904
Third gear: 38/32=1.181
Fourth gear: 31/38=0.815
Fifth gear: 33/38=0.868
Reverse gear: 39/12=3.25
Final drive; 69/17=4.058
In conclusion the manual transmission that i assessed is in working condition with only minor replacements needed. Only being the circlips.
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