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7 Transmission Repair
7E Tuff Torq K210A
Figure E-27. Measure Shift Shaft and Collar
Figure E-28. Measure Shift Fork
Figure E-30. Measure Axle Shaft OD
5. Inspect shift shaft for wear in shift key grooves.
6. Measure shift shaft in the following areas:
A. Shift Collar Groove Width: 6.1–6.2 mm
Shift Shaft OD at Gears: 31.915–31.935 mm
Shift Shaft OD at Shift Collar: 33.90–33.95 mm
Shift Collar Inside Diameter: 34.05–34.10 mm
Shift Collar-to-Shift Shaft Clearance: 0.1–0.2 mm
Shift Collar-to-Shift Fork Clearance:
New: 0.2–0.5 mm
Maximum: 1.0 mm
A
7. Measure shift fork in the following areas:
A. Shift Fork ID: 17.04–17.08 mm
B. Shift Fork Thickness: 5.7–5.9 mm
Shift Fork Width: 8.05–8.15 mm
Shift Fork-to-Shift Arm Pin Clearance:
New: 0.05–0.186 mm
Maximum: 1.0 mm
8. Measure fork shaft and case in the following areas:
Fork Shaft OD: 16.957–17.000 mm
Fork Shaft-to-Shift Fork Clearance: 0.040–0.123 mm
Case Bore ID at Fork Shaft: 17.016–17.043 mm
Fork Shaft to Case Bore Clearance:
New: 0.016-0.086 mm
Maximum: 0.5 mm
Fork Shaft End Float: 0–0.82 mm
B
9. Measure outside diameter of both left and right side
axle shaft in the following area:
A. Needle Bearing Rub Surface: 29.987–30.000 mm
10. Measure outside diameter of axle shaft in the follow-
ing area:
B. Right Side Axle Shaft–Differential Bushing
Contact Surface: 27.934–27.955 mm
B. Left Side Axle Shaft–Differential Case Contact
Surface: 24.959–24.980 mm
A
B
A
Figure E-29. Measure Fork Shaft
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