Mainshaft Assembly Clearance Inspection
Mainshaft Assembly Clearance InspectionNOTE: If replacement is required, always replace the synchro sleeve and hub as a set.
1. Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft (B).
2. Measure the clearance between 2nd (C) and 3rd (D) gears with a feeler gauge (E).
- If the clearance is more than the service limit, go tostep3.
- If the clearance is within the service limit, go to step 4.
Standard: 0.06 - 0.19 mm (0.002 - 0.007 inch)
Service Limit: 0.3 mm (0.01 inch)
3. Measure the thickness of 3rd gear.
- If the thickness is less than the service limit, replace 3rd gear.
- If the thickness is within the service limit, replace the 3rd/4th synchro hub/sleeve.
Standard: 23.89 - 23.97 mm (0.941 - 0.944 inch)
Service Limit: 23.8 mm (0.94 inch)
4. Measure the clearance between 4th gear (A) and the distance collar (B) with a dial indicator (C). If the clearance is more than the service limit, go to step 5.
Standard: 0.06 - 0.19 mm (0.002 - 0.007 inch)
Service Limit: 0.3 mm (0.01 inch)
5. Measure distance (1) on the 4th gear side distance collar.
- If distance (1) is not within the standard, replace the distance collar.
- If distance (1) is within the standard, go to step 6.
Standard: 22.53 - 22.58 mm (0.887 - 0.889 inch)
6. Measure the thickness of 4th gear.
- If the thickness is less than the service limit, replace 4th gear. If the thickness is within the service limit, replace the 3rd/4th synchro hub/sleeve.
Standard: 22.39 - 22.47 mm (0.881 - 0.885 inch)
Service Limit: 22.3 mm (0.88 inch)
7. Measure the clearance between the distance collar (A) and 5th gear (B) with a dial indicator (C). If the clearance is more than the service limit, go to step 8.
Standard: 0.06 - 0.19 mm (0.002 - 0.007 inch)
Service Limit: 0.3 mm (0.01 inch)
8. Measure distance (2) on the 5th gear side distance collar.
- If distance (2) is not within the standard, replace the distance collar.
- If distance (2) is within the standard, go to step 9.
Standard: 22.53 - 22.58 mm (0.887 - 0.889 inch)
9. Measure the thickness of 5th gear.
- If the thickness is less than the service limit, replace 5th gear.
- if the thickness is within the service limit, replace the 5th/6th synchro hub/sleeve.
Standard: 22.39 - 22.47 mm (0.881 - 0.885 inch)
Service Limit: 22.3 mm (0.88 inch)
10. Measure the clearance between 6th gear (A) and the angular ball bearing inner race (B) with a dial indicator (C) If the clearance is more than the service limit, go to step 11.
Standard: 0.06 - 0.19 mm (0.002 - 0.007 inch)
Service Limit: 0.3 mm (0.01 inch)
11. 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 12.
Standard: 22.03 - 22.08 mm (0.867 - 0.869 inch)
12. Measure the thickness of 6th gear.
- If the thickness is less than the service limit, replace 6th gear.
- If the thickness is within the service limit, replace the 5th/6th synchro hub/sleeve.
Standard: 21.89 - 21.97 mm (0.862 - 0.865 inch)
Service Limit: 21.8 mm (0.86 inch)