Countershaft Assembly Clearance Inspection
1. Countershaft Assembly Clearance - Inspect
1.
Measure the clearance between 1st gear (A) and the countershaft reverse gear (B) with a dial indicator (C).
If the clearance exceeds 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 (0.0024?0.0063 in)
Service Limit:
 
0.16 mm (0.0063 in)
2.
Measure the length of the countershaft reverse gear as shown.
If the length is not within the standard, replace the countershaft reverse gear.
If the length is within the standard, go to step 3.
Standard:
 
32.05?32.15 mm (1.2618?1.2657 in)
3.
Measure the thickness of 1st gear.
If the thickness is less than the service limit, replace 1st gear.
If the thickness within the service limit, replace the 1st/2nd synchro hub and the 1st/2nd synchro sleeve as a set.
Standard:
 
23.92?23.97 mm (0.9417?0.9437 in)
Service Limit:
 
23.92 mm (0.9417 in)
4.
Measure the clearance between 2nd gear (A) and 3rd gear (B) with a feeler gauge (C). If the clearance exceeds the service limit, go to step 5.
Standard:
 
0.06?0.21 mm (0.003?0.008 in)
Service Limit:
 
0.21 mm (0.008 in)
5.
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:
 
26.53?26.58 mm (1.0445?1.0465 in)
6.
Measure the thickness of 2nd gear as shown.
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 the 1st/2nd synchro sleeve as a set.
Standard:
 
29.42?29.47 mm (1.1583?1.1602 in)
Service Limit:
 
29.42 mm (1.1583 in)