M/T Countershaft Assembly Clearance Inspection

NOTE: Before inspection, make sure the 20 mm special bolt is tightened to the specified torque.

1.Measure the clearance between 1st gear (A) and the countershaft reverse gear (B) with a dial indicator (C). If the clearance is more than the service limit, go to 2.

Standard: 0.04-0.17 mm (0.002-0.007 in.) 
Service Limit: 0.28 mm (0.011 in.) 

 


2.Measure the thickness of the countershaft reverse gear.

  • If the thickness is less than the standard, replace the countershaft reverse gear.
  • 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 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/sleeve.

Standard: 22.91-22.99 mm (0.902-0.905 in.) 
Service Limit: 22.86 mm (0.900 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: 0.04-0.17 mm (0.002-0.007 in.) 
Service Limit: 0.28 mm (0.011 in.) 

 

5.Measure the thickness of the distance collar.

  • If the thickness is less than the standard, replace the distance collar.
  • If the thickness is within the standard, go to 6.

Standard: 23.03-23.08 mm (0.907-0.909 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: 22.91-22.99 mm (0.902-0.905 in.) 
Service Limit: 22.86 mm (0.900 in.)