M/T Mainshaft Assembly Clearance Inspection
NOTE: If replacement is required, always replace the synchro sleeve and hub as a set.
| 1. | Support the bearing inner race with a socket (A), and push down on the mainshaft (B).
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| 2. | Measure the clearance between 2nd (C) and 3rd (D) gears with a feeler gauge (E).
- If the clearance is more than the service limit, go to 3.
- If the clearance is within the service limit, go to 4.
| Standard: | 0.06-0.21 mm
(0.002-0.008 in.) | | Service Limit: | 0.33 mm (0.013 in.) |
 BCDEA |
| 3. | Measure the thickness of 3rd gear.
- If the thickness of 3rd gear is less than the service limit, replace 3rd gear with a new one.
- If the thickness of 3rd gear is within the service limit, replace the 3rd/4th synchro hub with a new one.
| Standard: | 27.92-27.97 mm
(1.099-1.101 in.) | | Service Limit: | 27.85 mm (1.096 in.) |
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| 4. | Measure the clearance between 4th gear (A) and the distance collar (B) with a dial indicator (C). If the clearance is more than the service limit, go to 5.
| Standard: | 0.06-0.19 mm
(0.002-0.007 in.) | | Service Limit: | 0.31 mm (0.012 in.) |
 CAB |
| 5. | Measure distance (1) on the spacer collar.
- If distance (1) is not within the standard, replace the distance collar with a new one.
- If distance (1) is within the standard, go to 6.
| Standard: | 24.03-24.06 mm
(0.946-0.947 in.) |
 (1) |
| 6. | Measure the thickness of 4th gear.
- If the thickness of 4th gear is less than the service limit, replace 4th gear with a new one.
- If the thickness of 4th gear is within the service limit, replace the 3rd/4th synchro hub with a new one.
| Standard: | 27.02-27.07 mm
(1.064-1.066 in.) | | Service Limit: | 26.95 mm (1.061 in.) |
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| 7. | Measure the clearance between the distance collar (A) and 5th gear (B) with a dial indicator (C). If the clearance is more than the service limit, go to 8.
| Standard: | 0.06-0.19 mm
(0.002-0.007 in.) | | Service Limit: | 0.31 mm (0.012 in.) |
 CAB |
| 8. | Measure distance (2) on the distance collar.
- If distance (2) is not within the standard, replace the distance collar with a new one.
- If distance (2) is within the standard, go to 9.
| Standard: | 24.03-24.06 mm
(0.946-0.947 in.) |
 (2) |
| 9. | Measure the thickness of 5th gear.
- If the thickness of 5th gear is less than the service limit, replace 5th gear with a new one.
- If the thickness of 5th gear is within the service limit, replace the 5th synchro hub with a new one.
| Standard: | 28.92-28.97 mm
(1.139-1.141 in.) | | Service Limit: | 28.85 mm (1.136 in.) |
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| 10. | Measure the thickness of the distance collar.
- If the thickness of distance collar is not within standard, replace the distance collar with a new one.
| Standard: | 12.00-12.05 mm
(0.472-0.474 in.) |
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