Countershaft Idler Gear and 4th Gear Axial Clearance Inspection

Countershaft Idler Gear and 4th Gear Axial Clearance Inspection

1. Install the 40.5 mm cotters (A), 2nd gear (B), thrust needle bearing (C), needle bearing (D), idler gear (E), thrust needle bearing (F), 61 mm washer (G), 1st gear (H), 4th gear (I), 50.8 mm collar (J), 50.8 mm washer (K), 42.2 mm cotters (L), cotter retainer (M), and snap ring (N) on the countershaft (O). Install the 40.5 mm cotters, idler gear, 1st gear, and 4th gear in the direction shown.






2. Insert a feeler gauge blade (A) as thick as possible between the 50.8 mm collar (B) and 50.8 mm washer (C).






3. Set the dial indicator (A) on the idler gear (B).






4. Measure the idler gear axial clearance in at least three places while moving the idler gear. Use the average as the actual clearance.

Standard: 0.005-0.040 mm (0.0002-0.0016 in.)

5. If the measurement is out of standard, remove the 61 mm washer and measure its thickness.

6. From the table below, select the proper washer. Then install the washer and recheck the clearance.

WASHER, 61 mm










7. Measure the clearance between the 50.8 mm collar (A) and the 50.8 mm washer (B) with a feeler gauge (C) in at least three places. Use the average as the actual clearance.

Standard: 0.005-0.040 mm (0.0002-0.0016 in.)

8. If the measurement is out of standard, remove the 50.8 mm washer and measure its thickness.

9. From the table below, select the proper washer. Then install the washer and recheck the clearance.

WASHER, 50.8 mm