M/T 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 2.

Standard: 0.06-0.16 mm (0.002-0.006 in.) 
Service Limit: 0.25 mm (0.010 in.) 

 

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 3.

Standard: 23.03-23.08 mm (0.907-0.909 in.) 

 

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 in.) 
Service Limit: 22.87 mm (0.900 in.) 

 

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 5.

Standard: 0.06-0.16 mm (0.002-0.006 in.) 
Service Limit: 0.25 mm (0.010 in.) 

 

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 6.

Standard: 28.03-28.08 mm (1.104-1.106 in.) 

 

6.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: 27.92-27.97 mm (1.099-1.101 in.) 
Service Limit: 27.87 mm (1.097 in.)