Countershaft Assembly Clearance Inspection

Countershaft Assembly Clearance Inspection





1. Measure the clearance between the 1st gear (A) and the distance collar (B) with a feeler gauge (C).
^ If the clearance is more than the service limit, go to step 2.
^ If the clearance is within the service limit, go to step 4.
Standard: 0.06 - 0.16 mm (0.002 - 0.006 inch)
Service Limit: 0.25 mm (0.010 inch)





2. Measure the thickness of the distance collar.
^ If the thickness is not within the standard, replace the distance collar with a new one.
^ If the thickness is within the standard, go to step 3.
Standard: 23.03 - 23.08 mm (0.907 - 0.909 inch)





3. Measure the thickness of the 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 1st/2nd synchro hub with a new one.
Standard: 22.92 - 22.97 mm (0.902 - 0.904 inch)
Service Limit: 22.87 mm (0.900 inch)





4. Measure the clearance between the 2nd gear (A) and 3rd gear (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 5.
Standard: 0.06 - 0.16 mm (0.002 - 0.006 inch)
Service Limit: 0.25 mm (0.010 inch)





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





6. Measure the thickness of the 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 2nd gear is within the service limit, replace the 1st/2nd synchro hub with a new one.
Standard: 27.92 - 27.97 mm (1.099 - 1.101 inch)
Service Limit: 27.87 mm (1.097 inch)