M/T Countershaft Assembly Clearance Inspection

1.Measure the clearance between 1st gear (A) and the distance collar (B) with a feeler gauge (C). If the clearance is more than the service limit, go to 2.

Standard: 0.06-0.21 mm (0.002-0.008 in.) 
Service Limit: 0.25 mm (0.010 in.) 

 


2.Measure the thickness of the distance collar.

  • If the thickness is not within than the standard, replace the distance collar.
  • If the thickness is within the standard, go to 3.

Standard: 21.53-21.58 mm (0.843-0.849 in.) 

 

3.Measure the thickness of 1st gear.

  • If the thickness is less than the service limit, replace 1st gear.
  • If the thickness is within the service limit, replace the 1st/2nd synchro hub.

Standard: 27.42-27.47 mm (0.902-0.904 in.) 

 

4.Measure the clearance between 2nd gear (A) and 3rd gear (B) with a feeler gauge (C). If the clearance is more than the service limit, go to 5.

Standard: 0.06-0.14 mm (0.002-0.006 in.) 
Service Limit: 0.23 mm (0.009 in.) 

 

5.Measure the thickness of the distance collar.

  • If the thickness is not within the standard, replace the distance collar.
  • If the thickness is within the standard, go to 6.

Standard: 26.53-26.56 mm (1.044-1.046 in.) 

 

6.Measure the thickness of 2nd gear.

  • If the thickness is less than the service limit, replace 2nd gear.
  • If the thickness is within the service limit, replace the 1st/2nd synchro hub.

Standard: 32.42-33.47 mm (1.316-1.318 in.)