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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 Step 2 .
    • 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:
    0.03−0.12 mm (0.001−0.005 in.)
    Service Limit:
    0.24 mm (0.009 in.)


  1. Measure the length of the 1st gear distance collar as shown.
    • If the thickness is not within than the standard, replace the distance collar.
    • If the thickness is within the standard, go to Step 3 .
    Standard:
    26.53−26.58 mm (1.044−1.046 in.)


  1. 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:
    27.42−27.47 mm (1.080−1.081 in.)
    Service Limit:
    27.39 mm (1.078 in.)


  1. 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 in.)
    Service Limit:
    0.24 mm (0.009 in.)


  1. 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 Step 5 .
    Standard:
    27.53−27.56 mm (1.084−1.085 in.)
    Service Limit:
    27.51 mm (1.083 in.)


  1. 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.)