M/T Mainshaft Assembly Clearance Inspection (M/T)

M/T Mainshaft Assembly Clearance Inspection

NOTE:

• If replacement is required, always replace the synchro sleeve and hub as a set.
  
• 6-speed model is shown, 5-speed model is similar.
  

1.	Support the bearing inner race with an appropriate sized socket (A), and push down on the mainshaft (B). EBCDA

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 3. If the clearance is within the service limit, go to 4. Standard:  0.06-0.16 mm (0.002-0.006 in.)  Service Limit:  0.25 mm (0.010 in.)

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 (0.941-0.944 in.)  Service Limit:  23.80 mm (0.937 in.)

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 5. Standard:  0.06-0.16 mm (0.002-0.006 in.)  Service Limit:  0.25 mm (0.010 in.)  CAB

5.	Measure distance (1) on the distance collar. If distance (1) is not within the standard, replace the distance collar with a new one. If distance (1) is within the standard, go to 6. Standard:  24.03-24.08 mm (0.946-0.947 in.)  (1)

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 (0.941-0.944 in.)  Service Limit:  23.80 mm (0.937 in.)

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 8. Standard:  0.06-0.16 mm (0.002-0.006 in.)  Service Limit:  0.25 mm (0.010 in.)  ABC

8.	Measure distance (2) on the distance collar. If distance (2) is not within the standard, replace the distance collar with a new one. If distance (2) is within the standard, go to 9. Standard:  24.03-24.08 mm (0.946-0.947 in.)  (2)

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 (0.941-0.944 in.)  Service Limit:  23.80 mm (0.937 in.)

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 11. Standard:  0.06-0.16 mm (0.002-0.006 in.)  Service Limit:  0.25 mm (0.010 in.)  ABC

11.

Measure the thickness of the distance collar. If the thickness of distance collar is not within the standard, replace the distance collar with a new one. If the thickness of distance collar is within the standard, go to 12 (6-speed model only). Standard:    5-speed model:  23.95-24.05 mm (0.943-0.947 in.)  6-speed model:  24.03-24.08 mm (0.946-0.948 in.)

12.

Measure the thickness of 6th gear. If the thickness of 6th gear is less than the service limit, replace 6th gear with a new one. If the thickness of 6th gear is within the service limit, replace the 5th/6th synchro hub with a new one. Standard:  23.92-23.97 mm (0.941-0.944 in.)  Service Limit:  23.80 mm (0.937 in.)