Mainshaft Assembly Clearance Inspection
InspectionNOTE: If replacement is required, always replace the synchro sleeve and hub as a set.
1. Support the bearing inner race with a 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 to step 3.
- If the clearance is within the service limit, go to step 4.
Standard: 0.06 - 0.21 mm (0.002 - 0.008 inch)
Service Limit: 0.3 mm (0.01 inch)
3. Measure the thickness of 3rd gear (A).
- If the thickness of 3rd gear is less than the service limit, replace 3rd gear with a new one.
- If the thickness of 3rd gear is within the service limit, replace the 3rd/4th synchro hub with a new one.
Standard: 32.42 - 32.47 mm (1.276 - 1.278 inch)
Service Limit: 32.3 mm (1.27 inch)
4. Measure the clearance between 4th gear (A) and the spacer collar (B) with a dial indicator (C). If the clearance is more than the service limit, go to step 5.
Standard: 0.06 - 0.21 mm (0.002 - 0.008 inch)
Service Limit: 0.3 mm (0.01 inch)
5. Measure distance (1) on the spacer collar.
- If distance (1) is less than the service limit, replace the spacer collar with a new one.
- If distance (1) is within the service limit, go to step 6.
Standard: 26.03 - 26.08 mm (1.025 - 1.027 inch)
Service Limit: 26.01 mm (1.024 inch)
6. Measure the thickness of 4th gear.
- If the thickness of 4th gear is less than the service limit, replace 4th gear with a new one.
- If the thickness of 4th gear is within the service limit, replace the 3rd/4th synchro hub with a new one.
Standard: 30.92 - 30.97 mm (1.217 - 1.219 inch)
Service Limit: 30.8 mm (1.21 inch)
7. Measure the clearance between the spacer 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 - 0.21 mm (0.002 - 0.008 inch)
Service Limit: 0.3 mm (0.01 inch)
8. Measure distance (a) on the spacer collar.
- If distance (a) is less than the service limit, replace the spacer collar with a new one.
- If distance (a) is within the service limit, go to step 9.
Standard: 26.03 - 26.08 mm (1.025 - 1.027 inch)
Service Limit: 26.01 mm (1.024 inch)
9. Measure the thickness of 5th gear.
- If the thickness of 5th gear is less than the service limit, replace 5th gear with a new one.
- If the thickness of 5th gear is within the service limit, replace the 5th synchro hub with a new one.
Standard: 30.92 - 30.97 mm (1.217 - 1.219 inch)
Service Limit: 30.8 mm (1.21 inch)