Countershaft Assembly Clearance Inspection

Inspection





1. Measure the clearance between the 1st gear (A) and the thrust washer (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 2.
Standard: 0.06 - 0.23 mm (0.002 - 0.009 inch)
Service Limit: 0.23 mm (0.009 inch)





2. Measure the thickness of the thrust washer.
- If the thickness is less than the standard, replace the thrust washer with a new one.
- If the thickness is within the standard, go to step 3.
Standard: 1.95 - 1.97 mm (0.077 - 0.078 inch)





3. Measure the thickness of the 1st gear.
- If the thickness of 1st gear is less than the standard, replace 1st gear with a new one.
- If the thickness of 1st gear is within the standard, replace the 1st/2nd synchro hub with a new one.
Standard: 32.95 - 33.00 mm (1.297 - 1.299 inch)





4. Measure the clearance between the 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: 0.10 - 0.15 mm (0.004 - 0.006 inch)
Service Limit: 0.18 mm (0.007 inch)





5. Measure the thickness of the spacer.
- If the thickness is less than the standard, replace the spacer with a new one.
- If the thickness is within the standard, go to step 6.
Standard: 29.07 - 29.09 mm (1.144 - 1.145 inch)





6. Measure the thickness of the 2nd gear.
- If the thickness of 2nd gear is less than the standard, replace 2nd gear with new one.
- If the thickness of 1st gear is within the standard, replace the 1st/2nd synchro hub with a new one.
Standard: 28.92 - 28.97 mm (1.139 - 1.141 inch)