M/T Mainshaft Assembly Clearance Inspection

M/T Mainshaft Assembly Clearance Inspection

NOTE:

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

- Support the bearing inner race, and push down on the mainshaft.

1. Measure the clearance between 3rd gear (A) and the ball bearing (B) with a feeler gauge.
- If the clearance exceeds the service limit, go to step 2.

- If the clearance is within the service limit, go to step 4.










2. Measure the length of the 3rd gear distance collar.
- If the length is not within the standard, replace the 3rd gear distance collar.

- If the length is within the standard, go to step 3.










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 and the 3rd/4th synchro sleeve as a set.





'00-03 models





'04-09 models





4. Measure the clearance between 4th gear (A) and the 4th/5th gear distance collar (B) with a feeler gauge.
- If the clearance exceeds the service limit, go to step 5.

- If the clearance is within the service limit, go to step 7.










5. Measure the length (1) of the 4th/5th gear distance collar as shown.
- If the length (1) is not within the standard, replace the 4th/5th gear distance collar.

- If the length (1) is within the standard, go to step 6.










6. Measure the thickness of 4th gear.
- If the thickness is less than service limit, replace 4th gear.

- If the thickness is within the service limit, replace the 3rd/4th synchro hub and the 3rd/4th synchro sleeve as a set.





'00-03 models





'04-09 models





7. Measure the clearance between 5th gear (A) and the 4th/5th gear distance collar (B) with a dial indicator.
- If the clearance exceeds the service limit, go to step 8.

- If the clearance is within the service limit, go to step 10.










8. Measure the length (2) of the 4th/5th gear distance collar as shown.
- If the length (2) is not within the standard, replace the 4th/5th gear distance collar.

- If the length (2) is within the standard, go to step 9.










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 and the 5th/6th synchro sleeve as a set.










10. Measure the clearance between 6th gear (A) and the mainshaft (B) with a dial indicator. If the clearance exceeds the service limit, go to step 11.










11. 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 and the 5th/6th synchro sleeve as a set.