Reassembly and Measurement

1. Remove both mainshaft and countershaft bearings from transmission housing.
2. Assemble mainshaft and countershaft including bearings and fifth gear components, as shown. Lubricate all parts with oil before final reassembly.
3. Install mainshaft/countershaft assembly into clutch housing.
4. Install the mainshaft holder to prevent shafts from turning, and shift transmission into gear.
5. Torque the countershaft and mainshaft locknuts to 90 N-m (9.0 kg-m, 65 lb-ft) before checking clearances.

CAUTION: Incorrect gear clearances can be caused by overtorquing the countershaft or mainshaft locknuts. Whenever locknuts are installed, use an accurately calibrated torque wrench.

6. Remove transmission shafts from clutch housing and measure clearances as described.

Mainshaft Measurements




7. Measure clearance between shoulder on third gear and shoulder on second gear.




8. If out of tolerance, measure thickness of third gear.
- If third gear is OK, replace synchronizer hub if necessary after all other measurements are complete.




9. Measure clearance between spacer collar and shoulder on fourth gear.




10. If out of tolerance, measure thickness of fourth gear.
- If fourth gear is OK, replace synchronizer hub if necessary after all other measurements are complete.




11. Measure clearance between spacer collar and shoulder on fifth gear.




12. If out of tolerance, measure thickness of fifth gear.
- If out of limit, replace fifth gear.




13. Measure clearance between 28 mm spacer washer and ball bearing.

Replacement Spacer Washers:

- If out of tolerance, change thickness of 28 mm spacer washer after measuring all other clearances.

Countershaft Measurements




14. Measure clearance between first gear thrust washer and shoulder on first gear.

Replacement Thrust Washers:

- If out of tolerance, change thickness of first gear thrust washer after measuring all other clearances.




15. Measure clearance between shoulder on third gear and shoulder on second gear.




16. If out of tolerance, measure thickness of second gear.
- If out of limit, replace second gear.
17. After all clearances have all been checked, and those out of limits corrected, reassemble transmission mainshaft and countershaft and recheck all clearances.
- If they are correct, disassemble fifth gear components and reinstall bearings in transmission housing.