M/T Countershaft Assembly Clearance Inspection
NOTE: Before inspection, make sure the 20 mm special bolt is tightened to the specified torque.
  1. Measure the clearance between 1st gear (A) and the countershaft reverse gear (B) with a dial indicator (C). If the clearance is more than the service limit, go to Step 2 .
    Standard:
    0.04−0.17 mm (0.002−0.007 in.)
    Service Limit:
    0.28 mm (0.011 in.)

  1. Measure the thickness of the countershaft reverse gear.
    • If the thickness is less than the standard, replace the countershaft reverse gear.
    • If the thickness is within the standard, go to Step 3 .
    Standard:
    23.03−23.08 mm (0.907−0.909 in.)

  1. Measure the thickness of 1st gear.
    • If the thickness is less than the service limit, replace 1st gear.
    • If the thickness is within the service limit, replace the 1st/2nd synchro hub/sleeve.
    Standard:
    22.91−22.99 mm (0.902−0.905 in.)
    Service Limit:
    22.86 mm (0.900 in.)

  1. Measure the clearance between 2nd gear (A) and 3rd gear (B) with a feeler gauge (C). If the clearance is more than the service limit, go to Step 5 .
    Standard:
    0.04−0.17 mm (0.002−0.007 in.)
    Service Limit:
    0.28 mm (0.011 in.)

  1. Measure the thickness of the distance collar.
    • If the thickness is less than the standard, replace the distance collar.
    • If the thickness is within the standard, go to Step 6 .
    Standard:
    23.03−23.08 mm (0.907−0.909 in.)

  1. Measure the thickness of 2nd gear.
    • 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.
    Standard:
    22.91−22.99 mm (0.902−0.905 in.)
    Service Limit:
    22.86 mm (0.900 in.)