Mainshaft Assembly Clearance Inspection
InspectionNOTE: 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).
Standard: 0.06 - 0.16 mm (0.002 - 0.006 inch)
Service Limit: 0.25 mm (0.010 inch)
2. 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.
3. Measure the thickness of 3rd gear.
^ If the thickness of 3rd gear is less than the service limit, replace 3rd gear with a new one.
^ If the thickness of 3rd gear is within the service limit, replace the 3rd/4th synchro hub with a new one.
Standard: 23.92 - 23.97 mm (0.981 - 0.944 inch)
Service Limit: 23.80 mm (0.937 inch)
4. Measure the clearance between 4th gear (A) and the spacer collar (B) with a dial indicator (C). If the clearance is more than the service limit, go to step 5.
Standard: 0.06 - 0.16 mm (0.002 - 0.006 inch)
Service Limit: 0.25 mm (0.010 inch)
5. Measure distance (A on the distance collar.
^ If distance (I) is not within the standard, replace the distance collar with a new one.
^ If distance I is within the standard, go to step 6.
Standard: 24.03 - 24.08 mm (0.946 - 0.947 inch)
6. Measure the thickness of 4th gear.
^ If the thickness of 4th gear is less than the service limit, replace 4th gear with a new one.
^ If the thickness of 4th gear is within the service limit, replace the 3rd/4th synchro hub with a new one.
Standard: 23.92 - 23.97 mm (0.981 - 0.944 inch)
Service Limit: 23.80 mm (0.937 inch)
7. 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 - 0.16 mm (0.002 - 0.006 inch)
Service Limit: 0.25 mm (0.010 inch)
8. Measure distance ~ on the distance collar.
^ If distance (if) is not within the standard, replace the distance collar with a new one.
^ If distance (a) is within the standard, go to step 9.
Standard: 24.03 - 24.08 mm (0.946 - 0.947 inch)
9. Measure the thickness of 5th gear.
^ If the thickness of 5th gear is less than the service limit, replace 5th gear with a new one.
^ If the thickness of 5th gear is within the service limit, replace the 5th synchro hub with a new one.
Standard: 23.92 - 23.97 mm (0.981 - 0.944 inch)
Service Limit: 23.80 mm (0.937 inch)
10. Measure the thickness of the MBS distance collar.
If the thickness of MBS distance collar is not within standard, replace the MBS distance collar with a new one.
Standard: 23.95 - 24.05 mm (0.943 - 0.947 inch)