Countershaft and Reverse Idle Gear Inspection

Countershaft and Reverse Idle Gear Inspection
^ Using micrometer, check diameter of countershaft (1) and needle bush (2) as shown. If measured value is out of specification, replace counter and/or bush.

Countershaft diameter (standard)

Countershaft diameter (standard):

^ Measure width a of low speed gear shift fork and groove width b of low speed gear synchronizer sleeve and then calculate clearance "c" as follows:

Clearance "c" = "b" - "a"

If clearance exceeds limit, replace fork bush (1) and sleeve.

Clearance "c" between fork and sleeve
Standard: 0.2 - 0.5 mm (0.008 - 0.020 inch)
Limit: 1.0 mm (0.039 inch)





^ Check clearance a between synchronizer ring (2) and gear (1), key slot width b in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.





^ Using cylinder gauge (1), check inside diameter of countershaft 1st and 2nd gears (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.





^ Check clearance between reverse idle gear (2) and lever (1) of reverse gear shift link.
If clearance exceeds limit, replace gear and lever.

Clearance between reverse idle gear and lever
Standard: 0.05 mm - 0.25 mm (0.002 - 0.010 inch)
Limit: 0.5 mm (0.020 inch)