Countershaft: Testing and Inspection

CLEARANCE INSPECTION

NOTE: If replacement is required, always replace the synchro sleeve and hub as a set.

1. Measure the clearance between the countershaft and 1st gear.
- Standard: 0.03 - 0.10 mm (0.001 - 0.004 inch)
- Service Limit: 0.22 mm (0.009 inch)
2. If the clearance is more than the service limit, measure the thickness of 1st gear.
- Standard: 30.41 - 30.44 mm (1.197 - 1.198 inch)
- Service Limit: 30.36 mm (1.195 inch)
- If the thickness of 1st gear is less than the service limit, replace 1st gear with a new one.
- If the thickness of 1 st gear is within the service limit, replace the 1st/2nd synchro hub with a new one.
3. Measure the clearance between 2nd and 3rd gears.
- Standard: 0.04 - 0.12 mm (0.002 - 0.005 inch)
- Service Limit: 0.24 mm (0.009 inch)
4. If the clearance is more than the service limit, measure the thickness of the spacer collar. Standard: 32.03 - 32.06 mm (1.261 - 1.262 inch)
5. If the thickness is less than the service limit, replace the spacer collar with a new one. If the thickness is within the service limit, measure the thickness of 2nd gear.
- Standard: 31.92 - 31.97 mm (1.257 - 1.259 inch)
- Service Limit: 31.85 mm (1.254 inch)
- If the thickness of 2nd gear is less than the service limit, replace 2nd gear with a new one.
- If the thickness of 2nd gear is within the service limit, replace the 1st/2nd synchro hub with a new one.