Mainshaft Assembly Clearance Inspection
Mainshaft Assembly Clearance 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).
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.
Standard: 0.06 - 0.16 mm (0.002 - 0.006 inch)
Service Limit: 0.25 mm (0.010 inch)
3. Measure the thickness of 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.
Standard: 23.92 - 23.97 mm (0.941 - 0.944 inch)
Service Limit: 23.80 mm (0.937 inch)
4. 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 - 0.16 mm (0.002 - 0.006 inch)
Service Limit: 0.25 mm (0.010 inch)
5. Measure distance (1) on the 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: 24.03 - 24.08 mm (0.946 - 0.948 inch)
6. 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.
Standard: 23.92 - 23.97 mm (0.941 - 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 (2) on the 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: 24.03 - 24.08 mm (0.946 - 0.948 inch)
9. 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/6th synchro hub.
Standard: 23.92 - 23.97 mm (0.941 - 0.944 inch)
Service Limit: 23.80 mm (0.937 inch)
10. Measure the clearance between the 6th gear (A) and angular ball bearing (B) with a feeler gauge (C). If the clearance is more than the service limit, go to step 11.
Standard: 0.06 - 0.16 mm (0.002 - 0.006 inch)
Service Limit: 0.25 mm (0.010 inch)
11. Measure the thickness of the distance collar.
- If the thickness is not within the standard, replace the distance collar.
- If the thickness is within the standard, go to step 12.
Standard: 24.03 - 24.08 mm (0.946 - 0.948 inch)
12. Measure the thickness of 6th gear.
- If the thickness is less than the service limit, replace 6th gear.
- If the thickness is within the service limit, replace the 5th/6th synchro hub.
Standard: 23.92 - 23.97 mm (0.941 - 0.944 inch)
Service Limit: 23.80 mm (0.937 inch)