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 (C) and 3rd (D) gears 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 the 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 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 thickness of the distance collar.
   If the thickness is less than the standard, replace the distance collar.

   Standard: | 21.95−22.05 mm (0.864−0.868 in.)