M/T Countershaft Assembly Clearance Inspection

NOTE: 6-speed model is shown, 5-speed model is similar.

1. Measure the clearance between the 1st gear (A) and the distance collar (B) with a feeler gauge (C). If the clearance is more than the service limit, go to Step 2 .

   Standard: | 0.06−0.16 mm (0.002−0.006 in.)
   Service Limit: | 0.25 mm (0.010 in.)

1. Measure the thickness of the distance collar.
   - If the thickness is not within than the standard, replace the distance collar with a new one.
   - If the thickness is within the standard, go to Step 3 .

   Standard: | 23.03−23.08 mm (0.907−0.909 in.)

1. 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: | 22.92−22.97 mm (0.902−0.904 in.)
   Service Limit: | 22.87 mm (0.900 in.)

1. 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 Step 5 .

   Standard: | 0.06−0.16 mm (0.002−0.006 in.)
   Service Limit: | 0.25 mm (0.010 in.)

1. Measure the thickness of the distance collar.
   - If the thickness is not within the standard, replace the distance collar with a new one.
   - If the thickness is within the standard, go to Step 6 .

   Standard: | 28.03−28.08 mm (1.104−1.106 in.)

1. 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: | 27.92−27.97 mm (1.099−1.101 in.)
   Service Limit: | 27.87 mm (1.097 in.)