Countershaft Assembly Clearance Inspection
Countershaft Assembly Clearance InspectionNOTE: Before inspection, check that the 20 mm special bolt is tightened to the specified torque.
1. Measure the clearance between 1st gear (A) and the countershaft reverse gear (B) with a dial indicator (C). If the clearance is more than the service limit, go to step 2.
Standard: 0.04 - 0.17 mm (0.002 - 0.007 inch)
Service Limit: 0.28 mm (0.011 inch)
2. Measure the distance of the countershaft reverse gear.
If the distance is less than the standard, replace the countershaft reverse gear. If the thickness is within the standard, go to step 3.
Standard: 23.03 - 23.08 mm (0.907 - 0.909 inch)
3. Measure the thickness of 1st gear.
- If the thickness is less than the service limit replace 1st gear.
- If the thickness within the service limit, replace the 1st/2nd synchro hub/sleeve.
Standard: 22.91 - 22.99 mm (0.902 - 0.905 inch)
Service Limit: 22.86 mm (0.900 inch)
4. Measure clearance between 2nd gear (A) and 3rd gear (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 5.
Standard: 0.04 - 0.17 mm (0.002 - 0.007 inch)
Service Limit: 0.28 mm (0.011 inch)
5. Measure the thickness of the distance collar.
- If the thickness is less than the standard, replace the distance collar.
- If the thickness is within the standard, go to step 6.
Standard: 23.03 - 23.08 mm (0.907 - 0.909 inch)
6. Measure the thickness of 2nd gear.
- If the thickness is less than the service limit, replace 2nd gear.
- If the thickness is within the service limit, replace the 1st/2nd synchro hub.
Standard: 22.91 - 22.99 mm (0.902 - 0.905 inch)
Service Limit: 22.86 mm (0.900 inch)