Mainshaft: Testing and Inspection

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





1. Measure the clearance between 2nd and 3rd gears.
- Standard: 0.06 - 0.21 mm (0.002 - 0.008 inch)
- Service Limit: 0.33 mm (0.013 inch)





2. If the clearance is more than the service limit, measure the thickness of 3rd gear.
- Standard: 30.22 - 30.27 mm (1.190 - 1.192 inch)
- Service Limit: 30.15 mm (1.187 inch)
- 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.





3. Measure the clearance between 4th gear and the spacer collar.
- Standard: 0.06 - 0.19 mm (0.002 - 0.007 inch)
- Service Limit: 0.31 mm (0.012 inch)





4. If the clearance is more than the service limit, measure distance (A) on the spacer collar.
- Standard: 22.82 - 22.86 mm (0.898 - 0.900 inch)
- Service Limit: 22.81 mm (0.898 inch)





5. If distance (A) is less than the service limit, replace the spacer collar with a new one. If distance (A) is within the service limit, measure the thickness of 4th gear.
- Standard: 30.12 - 30.17 mm (1.186 - 1.188 inch)
- Service limit: 30.05 mm (1.183 inch)
- 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.





6. Measure the clearance between the spacer collar and 5th gear.
- Standard: 0.06 - 0.19 mm (0.002 - 0.007 inch)
- Service Limit: 0.31 mm (0.012 inch)





7. If the clearance is more than the service limit, measure distance (B) on the spacer collar.
- Standard: 23.53 - 23.56 mm (0.926 - 0.928 inch)
- Service Limit: 23.51 mm (0.926 inch)





8. If distance (B) is less than the service limit, replace the spacer collar with a new one. If distance (B) is within the service limit, measure thickness of 5th gear.
- Standard: 28.42 - 28.47 mm (1.119 - 1.121 inch)
- Service Limit: 28.35 mm (1.116 inch)
- 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.