Inspection

1. Inspect the gear surfaces and bearing surfaces for wear or damage, then measure the countershaft at points A, B and C.

Standard:   A: 30.000-30.015 mm
(1.1811-1.1817 in) B: 35.984-36.000 mm
(1.4167-1.4173 in) C: 24.980-24.993 mm
(0.9835-0.9840 in)
Service Limit: A: 29.95 mm (1.1791 in) B: 35.93 mm (1.4146 in) C: 24.93 mm (0.9815 in)

If any part of the countershaft is less than the service limit, replace it with a new one.

2. Inspect for runout.

Standard:   0.02 mm (0.0008 in) min. Service Limit: 0.05 mm (0.0020 in)

If the runout exceeds the service limit, replace the countershaft with a new one.
Reassembly -
CAUTION:
•   Press the 3rd, 4th and 5th gears on the countershaft without lubrication.
•   When installing the 3rd, 4th and 5th gears, support the shaft on steel blocks and install the gears using a press.
1. Install the needle bearing on the countershaft.
2. Assemble the parts below as shown.

NOTE: Check that the finger of the friction damper is securely set in the groove of the 1 st/2nd synchro hub.

3. Place the parts assembled in Step 2, then install the parts on the countershaft.