7. 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 a socket (A), and push down on the mainshaft (B).
Standard: 0.06 - 0.21 mm (0.002 - 0.008 inch)
Service Limit: 0.33 mm (0.013 inch)
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.
3. Measure the thickness of 3rd gear.
^ 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: 27.92 - 27.97 mm (1.099 - 1.101 inch)
Service Limit: 27.85 mm 0.096 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 - 0.19 mm (0.002 - 0.007 inch)
Service Limit: 0.31 mm (0.012 inch)
5. Measure distance (1) on the spacer collar.
If distance (1) is not within the standard, replace the spacer collar with a new one. If distance (2) is within the standard, go to step 6.
Standard: 24.03 - 24.06 mm (0.946 - 0.947 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: 27.02 - 27.07 mm (1.064 - 1.066 inch)
Service Limit: 26.95 mm (1.061 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 - 0.19 mm (0.002 - 0.007 inch)
Service Limit: 0.31 mm (0.012 inch)
8. Measure distance (1) on the spacer collar.
^ If distance (1) is not within the standard, replace the spacer collar with a new one.
^ If distance (9) is within the standard, go to step 9.
Standard: 24.03 - 24.06 mm (0.946 - 0.947 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: 28.92 - 28.97 mm (1.139 - 1.141 inch)
Service Limit: 28.85 mm (1.136 inch)