M/T 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 2.

Standard: 0.03-0.12 mm (0.001-0.005 in.) 
Service Limit: 0.22 mm (0.009 in.) 

 

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: 26.89-26.94 mm (1.059-1.061 in.) 
Service Limit: 26.86 mm (1.057 in.) 

 

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 4.

Standard: 0.04-0.12 mm (0.002-0.005 in.) 
Service Limit: 0.24 mm (0.009 in.) 

 

4.Measure the thickness of the distance collar.

  • If the thickness is less than the service limit, replace the distance collar with a new one.
  • If the thickness is within the service limit, go to 5.

Standard: 27.53-27.56 mm (1.084-1.085 in.) 
Service Limit: 27.51 mm (1.083 in.) 

 

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 in.) 
Service Limit: 27.36 mm (1.077 in.)