M/T Mainshaft Assembly Clearance Inspection
NOTE: If replacement is required, always replace the synchro sleeve and hub as a set.
  1. Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft (B).
  1. Measure the clearance between 2nd gear (C) and 3rd gear (D) with a feeler gauge (E).
    • If the clearance is more than the service limit, go to Step 3 .
    • If the clearance is within the service limit, go to Step 4 .
    Standard:
    0.06−0.19 mm (0.002−0.007 in.)
    Service Limit:
    0.3 mm (0.01 in.)

  1. Measure the thickness of 3rd gear.
    • If the thickness is less than the service limit, replace 3rd gear.
    • If the thickness is within the service limit, replace the 3rd/4th synchro hub/sleeve.
    Standard:
    23.89−23.97 mm (0.941−0.944 in.)
    Service Limit:
    23.8 mm (0.94 in.)

  1. Measure the clearance between 4th gear (A) and the distance collar (B) with a dial indicator (C). If the clearance is more than the service limit, go to Step 5 .
    Standard:
    0.06−0.19 mm (0.002−0.007 in.)
    Service Limit:
    0.3 mm (0.01 in.)

  1. Measure distance (1) on the 4th gear side distance collar.
    • If distance (1) is not within the standard, replace the distance collar.
    • If distance (1) is within the standard, go to Step 6 .
    Standard:
    22.53−22.58 mm (0.887−0.889 in.)

  1. Measure the thickness of 4th gear.
    • If the thickness is less than the service limit, replace 4th gear.
    • If the thickness is within the service limit, replace the 3rd/4th synchro hub/sleeve.
    Standard:
    22.39−22.47 mm (0.881−0.885 in.)
    Service Limit:
    22.3 mm (0.88 in.)

  1. Measure the clearance between the distance collar (A) and 5th gear (B) with a dial indicator (C). If the clearance is more than the service limit, go to Step 8 .
    Standard:
    0.06−0.19 mm (0.002−0.007 in.)
    Service Limit:
    0.3 mm (0.01 in.)

  1. Measure distance (2) on the 5th gear side distance collar.
    • If distance (2) is not within the standard, replace the distance collar.
    • If distance (2) is within the standard, go to Step 9 .
    Standard:
    22.53−22.58 mm (0.887−0.889 in.)

  1. Measure the thickness of 5th gear.
    • If the thickness is less than the service limit, replace 5th gear.
    • If the thickness is within the service limit, replace the 5th/6th synchro hub/sleeve.
    Standard:
    22.39−22.47 mm (0.881−0.885 in.)
    Service Limit:
    22.3 mm (0.88 in.)

  1. Measure the clearance between 6th gear (A) and the angular ball bearing inner race (B) with a dial indicator (C). If the clearance is more than the service limit, go to Step 11 .
    Standard:
    0.13−0.26 mm (0.005−0.010 in.)
    Service Limit:
    0.3 mm (0.01 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 12 .
    Standard:
    24.03−24.08 mm (0.946−0.948 in.)

  1. Measure the thickness of 6th gear.
    • If the thickness is less than the service limit, replace 6th gear.
    • If the thickness is within the service limit, replace the 5th/6th synchro hub/sleeve.
    Standard:
    23.82−23.90 mm (0.938−0.941 in.)
    Service Limit:
    23.8 mm (0.94 in.)