Clearance Inspection

1. Measure the clearance between countershaft and 1st gear.

Standard:   0.03-0.10 mm (0.001-0.004 in) Service Limit: 0.22 mm (0.009 in)

2. If the clearance exceeds the service limit, measure the thickness of 1st gear.

Standard:   30.41-30.44 mm (1.197-1.198 in) Service Limit: 30.36 mm (1.195 in)
If the thickness of 1st gear is less than the service limit, replace 1st gear with a new one. If the thickness of 1 st gear is within the service limit, replace the 1st/2nd synchro hub with a new one.

3. Measure the clearance between 2nd and 3rd gears.

Standard:   0.03-0.11 mm (0.001 -0.004 in) Service Limit: 0.23 mm (0.009 in)

4. If the clearance exceeds the service limit, measure distance ® on the spacer collar.

Standard:   32.03-32.06 mm (1.261-1.262 in) Service Limit: 32.01 mm (1.260 in)

5. If distance ® is more than the service limit, replace the spacer collar with a new one.
If distance ® is within the service limit, measure the thickness of 2nd gear.

Standard:   31.92-31.97 mm (1.257-1.259 In) Service Limit: 31.85 mm (1.254 in)

If the thickness of 2nd gear is less than the service limit, replace 2nd gear with a new one. If the thickness of 2nd gear is within the service limit, replace the spacer collar with a new one.