Clearance

NOTE: If replacement is required, always replace the synchro sleeve and hub as a set.

1. Support the bearing inner race with a socket, and push down on the mainshaft.





2. Measure the clearance between 2nd and 3rd gears.
- Standard: 0.06 - 0.21 mm (0.002 - 0.008 inch)
- Service Limit: 0.3 mm (0.01 inch)





3. If the clearance is more than the service limit, measure the thickness of 3rd gear.
- Standard: 34.92 - 34.97 mm (1.375 - 1.377 inch)
- Service Limit: 34.8 mm (1.370 inch)
- 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.





4. Measure the clearance between 4th gear and the spacer collar.
- Standard: 0.06 - 0.21 mm (0.002 - 0.008 inch).
- Service Limit: 0.3 mm (0.01 inch).





5. If the clearance is more than the service limit, measure distance (A) on the spacer collar.
- Standard: 26.03 - 26.08 mm (1.025 - 1.027 inch).
- Service Limit: 26.01 mm (1.024 inch).





6. If distance (A) is less than the service limit, replace the spacer collar with a new one. If distance (A) is within the service limit, measure the thickness of 4th gear.
- Standard: 31.42 - 31.47 mm (1.237 - 1.339 inch).
- Service Limit: 31.30 mm (1.23 inch).
- 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.





7. Measure the clearance between the spacer collar and 5th gear.
- Standard: 0.06 - 0.21 mm (0.002 - 0.008 inch).
- Service Limit: 0.3 mm (0.01 inch).





8. If the clearance is more than the service limit, measure distance (B) on the spacer collar.
- Standard: 26.03 - 26.08 mm (1.025 - 1.027 inch).
- Service Limit: 26.01 mm (1.024 inch).





9. If distance (B) is less than the service limit, replace the spacer collar with a new one. If distance (B) is within the service limit, measure the thickness of 5th gear.
- Standard: 30.92 - 30.97 mm (1.217 - 1.219 inch).
- Service Limit: 30.8 mm (1.21 inch).
- 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.