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 Step 2 .
    • If the clearance is within the service limit, go to Step 4 .
    Standard:
    0.06−0.16 mm (0.002−0.006 in.)
    Service Limit:
    0.25 mm (0.010 in.)

  1. Measure the length of the 1st gear distance collar as shown.
    • If the length is not within the standard, replace the 1st gear distance collar.
    • If the length is within the standard, go to Step 3 .
    Standard:
    23.03−23.08 mm (0.907−0.909 in.)

  1. 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 and reverse gear as a set.
    Standard:
    22.92−22.97 mm (0.902−0.904 in.)
    Service Limit:
    22.87 mm (0.900 in.)

  1. 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 Step 5 .
    Standard:
    0.06−0.16 mm (0.002−0.006 in.)
    Service Limit:
    0.25 mm (0.010 in.)

  1. Measure the length of the 2nd gear distance collar.
    • If the length is not within the standard, replace the 2nd gear distance collar.
    • If the length is within the standard, go to Step 6 .
    Standard:
    28.03−28.08 mm (1.104−1.106 in.)

  1. 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 and reverse gear as a set.
    Standard:
    27.92−27.97 mm (1.099−1.101 in.)
    Service Limit:
    27.87 mm (1.097 in.)