M/T Countershaft Assembly Clearance Inspection

1.	Measure the clearance between the 1st gear (A) and the countershaft (B) with a feeler gauge (C). If the clearance is more than the service limit, go to 2. Standard:  0.03-0.12 mm (0.001-0.005 in.)  Service Limit:  0.22 mm (0.009 in.)

2.

Measure the thickness of the 1st gear. If the thickness of 1st gear is less than the service limit, replace 1st gear with a new one. If the thickness of 1st gear is within the service limit, replace the 1st/2nd synchro hub with a new one. Standard:  26.89-26.94 mm (1.059-1.061 in.)  Service Limit:  26.86 mm (1.057 in.)

3.	Measure the clearance between the 2nd gear (A) and 3rd gear (B) with a feeler gauge (C). If the clearance is more than the service limit, go to 4. Standard:  0.04-0.12 mm (0.002-0.005 in.)  Service Limit:  0.24 mm (0.009 in.)

4.	Measure the thickness of the distance collar. If the thickness is less than the service limit, replace the distance collar with a new one. If the thickness is within the service limit, go to 5. Standard:  27.53-27.56 mm (1.084-1.085 in.)  Service Limit:  27.51 mm (1.083 in.)

5.

Measure the thickness of the 2nd gear. If the thickness of 2nd gear is less than the service limit, replace 2nd gear with new one. If the thickness of 1st gear is within the service limit, replace the 1st/2nd synchro hub with a new one. Standard:  27.41-27.46 mm (1.079-1.081 in.)  Service Limit:  27.36 mm (1.077 in.)