Countershaft: Testing and Inspection
CLEARANCE INSPECTIONNOTE: If replacement is required, always replace the synchro sleeve and hub as a set.
1. Measure the clearance between the 1st gear and thrust washer.
- Standard: 0.06 - 0.23 mm (0.002 - 0.009 inch).
- Service Limit: 0.23 mm (0.009 inch).
2. If the clearance is more than the service limit, measure the thickness of the thrust washer.
- Standard: 1.95 - 1.97 mm (0.077 - 0.078 inch).
3. If the thickness is less than the standard, replace the thrust washer with a new one. If the thickness is within the service limit, measure the thickness of the 1st gear.
- Standard: 32.95 - 33.00 mm (1.297 -1.299 inch).
- If the thickness of 1st gear is less than the standard, replace 1st gear with a new one.
- If the thickness of 1st gear is within the standard, replace 1st/2nd synchro hub with a new one.
4. Measure the clearance between the 2nd gear and 3rd gear.
- Standard: 0.10 - 0.15 mm (0.004 - 0.006 inch).
- Service Limit: 0.18 mm (0.007 inch)
5. If the clearance is more than the service limit, measure the thickness of the spacer.
- Standard: 29.07 - 29.09 mm (1.144 - 1.145 inch)
6. If the thickness is less than the standard, replace the spacer with a new one. If the thickness is within the standard, measure the thickness of the 2nd gear.
- Standard: 28.92-28.97 mm (1.139 - 1.141 inch).
- If the thickness of 2nd gear is less than the standard, replace 2nd gear with a new one.
- If the thickness of 1st gear is within the standard, replace 1st/2nd synchro hub with a new one.