M/T Countershaft Assembly Clearance Inspection

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