11. Countershaft Assembly Clearance Inspection

Countershaft Assembly Clearance Inspection





1. Measure the clearance between the 1st gear (A) and the countershaft (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 2.
Standard: 0.03 - 0.12 mm (0.001 - 0.005 inch)
Service Limit: 0.22 mm (0.009 inch)





2. 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:
'01 model: 26.91 - 26.94 mm (1.059 - 1.061 inch)
'02-03 models: 26.89 - 26.94 mm (1.058 - 1.061 inch)
Service Limit:
'01 model: 26.86 mm (1.057 inch)
'02-03 models: 26.86 mm (1.057 inch)





3. 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 4.
Standard: 0.04 - 0.12 mm (0.002 - 0.005 inch)
Service Limit: 0.24 mm (0.009 inch)





4. Measure the thickness of the spacer collar.
^ If the thickness is less than the service limit, replace the spacer collar with a new one.
^ If the thickness is within the service limit, go to step 5.
Standard: 27.53 - 27.56 mm (1.084 - 1.085 inch)
Service Limit: 27.51 mm (1.083 inch)





5. Measure the thickness of the 2nd gear.
^ If the thickness of 2nd gear is less than the service limit, replace 2nd gear with new one.
^ If the thickness of 1st gear is within the service limit, replace the 1st/2nd synchro hub with a new one.
Standard: 27.41 - 27.46 mm (1.079 - 1.081 inch)
Service Limit: 27.36 mm (1.077 inch)