Countershaft Assembly Clearance Inspection

Inspection





NOTE: If replacement is required, always replace the synchro sleeve and hub as a set.





1. Measure the clearance between 2nd gear (A) and the countershaft (B) with a feeler gauge. 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: 0.3 mm (0.012 inch)





2. Measure the thickness of 2nd gear.
^ If the thickness of 2nd gear is less than the service limit, replace 2nd gear with a new one.
^ If the thickness of find gear is within the service limit, replace the 1-2 synchro hub with a new one.
Standard: 32.88 - 32.96 mm (1.294 - 1.298 inch)
Service Limit: 32.76 mm (1.290 inch)





3. Measure the clearance between 1st gear (A) and the distance collar (B). If the clearance is more than the service limit, go to step 4.
Standard: 0.04 - 0.22 mm (0.002 - 0.009 inch)
Service Limit: 0.3 mm (0.012 inch)





4. Measure distance (1) on the distance collar.
^ If distance (1) is not within the standard, replace the distance collar with a new one.
^ If distance (1) is within the standard, go to step 5.
Standard: 28.03 - 28.08 mm (1.104 - 1.106 inch)





5. Measure the thickness of 1st gear.
^ If the thickness of 1st gear is less than the service limit, replace 1st gear with a new one.
^ If the thickness of 1st gear is within the service limit, replace the 1-2 synchro hub with a new one.
Standard: 31.18 - 31.26 mm (1.228 - 1.231 inch)
Service Limit: 31.06 mm (1.223 inch)





6. Measure the clearance between reverse gear (A) and the distance collar (B). If the clearance is more than the service limit, go to step 7.
Standard: 0.04 - 0.22 mm (0.002 - 0.009 inch)
Service Limit: 0.3 mm (0.012 inch)





7. Measure distance (1) on the distance collar.
^ If distance (1) is not within the standard, replace the distance collar with a new one.
^ If distance (1) is within the standard, go to step 8.
Standard: 25.53 - 25.58 mm (1.005 - 1.007 inch)





8. Measure the thickness of reverse gear.
^ If the thickness of reverse gear is less than the service limit, replace reverse gear with a new one.
^ If the thickness of reverse gear is within the service limit, replace the reverse synchro hub with a new one.
Standard: 26.38 - 26.46 mm (1.039 - 1.042 inch)
Service Limit: 26.26 mm (1.034 inch)