Countershaft and Reverse Idle Gear Inspection
Countershaft and Reverse Idle Gear InspectionReference: Manual Transmission Assembly Dismounting and Remounting
Reference: Manual Transmission Unit Disassembly
Reference: Countershaft and Reverse Idle Gear Disassembly and Assembly
^ Using micrometer, check diameter of countershaft as shown. If measured valve is out of specification, replace it.
^ Measure width a of 5th gear shift fork and groove width b of 5th gear synchronizer sleeve and then calculate clearance c as follows:
Clearance "c" = "b" - "a"
If clearance exceeds limit, replace fork and sleeve.
Check the following clearance and gear tooth.
^ Between synchronizer ring and synchronizer dog.
^ Between chamfered tooth of synchronizer dog and synchronizer ring.
If clearance exceed limit, replace with new one.
Clearance between synchronizer ring and synchronizer dog (countershaft)
Standard: 0.68 - 1.32 mm (0.027 - 0.052 inch)
Service limit: 0.5 mm (0.020 inch)
^ Using cylinder gauge (1), check inside diameter of countershaft 5th gear (2). If measured value exceeds specification, replace countershaft 5th gear.
^ Check oil clearance between reverse idle gear (2) and shaft (1) measuring inside diameter (a) of gear and diameter (b) of shaft and calculate as follows:
Clearance "c" = "b" - "a"
If clearance exceeds limit, replace gear and shaft.
Oil clearance "c" between reverse idle gear and shaft
Standard: 0.040 - 0.082 mm (0.0016 - 0.0032 inch)
Limit: 0.13 mm (0.005 inch)
^ Check clearance between reverse idle gear (2) and shoe (1) of reverse gear shift arm.
If clearance exceeds limit, replace shoe.
