Counter Gear: Testing and Inspection

COUNTER GEAR AND REVERSE IDLER GEAR COMPONENT PARTS INSPECTION
1. Inspect counter 5th gear radial clearance, as follows:
a. Install the spacer, counter 5th gear and needle roller bearing to the counter gear.





b. Using a dial indicator, measure the counter 5th gear radial clearance.
Standard clearance: 0.009-0.060 mm (0.0004-0.0024 inch).
Maximum clearance: 0.150 mm (0.0059 inch).
If the clearance exceeds the maximum, replace the counter gear, needle roller bearing or counter 5th gear.





2. Inspect counter gear. Using a micrometer, measure the outer diameter of the counter shaft journal.
Minimum diameter:
Part A: 26.975 mm (1.0620 inch).
Part B: 29.950 mm (1.1791 inch).
If the outer race is less than the minimum, replace the counter gear.





3. Inspect reverse idler gear radial clearance. Using a dial indicator, measure the reverse idler gee. radial clearance.
Standard clearance: 0.041-0.074 mm (0.0016-0.0029 inch).
Maximum clearance: 0.194 mm (0.0076 inch).
If the clearance exceeds the maximum, replace the gear or shaft.





4. Inspect reverse idler gear and shift arm shoe clearance. Using a feeler gauge, measure the clearance between the reverse idler gear and shift arm shoe.
Standard clearance: 0.20-0.41 mm (0.0079-0.0161 inch).
Maximum clearance: 0.90 mm (0.0354 inch).
If the clearance exceeds the maximum, replace the shift arm shoe or reverse idler gear.
5. Inspect 5th gear synchronizer ring, as follows:
a. Check for wear or damage.





b. Install the synchronizer pull ring, cone ring and outer ring to the 5th gear.





c. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If it does not lock, replace the synchronizer ring.





6. Inspect shift fork and hub sleeve clearance. Using a feeler gauge, measure the clearance between the hub sleeves and shift forks.
Maximum clearance: 1.0 mm (0.039 inch).
If the clearance exceeds the maximum, replace the shift fork or hub sleeve. While pushing three shifting keys, install the synchronizer ring assembly to the No.3 hub sleeve.