Clearance Inspection
1. Measure the clearance between 2nd and 3rd gears.
Standard: 0.06 — 0.21 mm
(0.002-0.008 in)
Service Limit: 0.3 mm (0.012 in)
2ND GEAR
3RD GEAR
2. If the clearance exceeds the service limit, measure
the thickness of 3rd gear.
Standard: 35.92 — 35.97 mm
(1.414-1.416 in)
Service Limit: 35.80 mm (1.409 in)
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.
3. Measure the clearance between 4th gear and the
spacer collar.
Standard: 0.06—0.21 mm
(0.002-0.008 in)
Service Limit: 0.3 mm (0.012 in)
4TH GEAR
5TH GEAR
4. If the clearance exceeds the service limit, measure
distance on the spacer collar.
Standard: 29.53 — 29.58 mm
(1.163-1.165 in)
Service Limit: 29.51 mm (1.162 in)
SPACER
COLLAR
4TH GEAR
“SIDE
5. If distance is less than the service limit, replace
the spacer collar with a new one.
If distance is within the service limit, measure
the thickness of 4th gear.
Standard: 35.92-35.97 mm
(1.414-1.416 in)
Service Limit: 35.80 mm (1.409 in)
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.
4TH
GEAR
6. Measure the clearance between the spacer collar
and 5th gear.
Standard: 0.06—0.21 mm
(0.002-0.008 in)
Service Limit: 0.3 mm (0.012 in)
4TH GEAR
5TH GEAR
7. If the clearance exceeds the service limit, measure
distance on the spacer collar.
Standard: 28.53—28.58 mm
(1.123-1.125 in)
Service Limit: 28.51 mm (1.122 in)
5TH GEAR
SIDE
SPACER
COLLAR
8. If distance is less than the service limit, replace
the spacer collar with a new one.
If distance is within the service limit, measure
thickness of 5th gear.
Standard: 34.92-34.97 mm
(1.375-1.377 in)
Service Limit: 34.80 mm (1.370 in)
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.