Escort L4-110 1.8L DOHC (1994)
Countershaft: Testing and Inspection
INSPECTION
1. Inspect gears for worn or damaged synchronizer cone, hub sleeve coupling, gear teeth, or inner and end surfaces.
2. Inspect input shaft gear assembly as follows:
a. Clearance between third and second gears is 0.0020-0.0098 inch.
b. Clearance between fourth gear and bearing cone is 0.0064-0.0163 inch.
3. Inspect input shaft for worn teeth, then check runout by mounting in a lathe or V-blocks. Maximum allowable runout is 0.002 inch.
4. Inspect main shaft gear assembly as follows:
a. Clearance between first gear and differential drive gear is 0.002-0.O19 inch.
b. Clearance between second gear and main third gear is 0.0069-0199 inch.
5. Inspect main shaft for the following conditions:
a. Ensure there are no worn or damaged gear contact surfaces, splines, or gear teeth.
b. Ensure oil passages are not clogged.
Mainshaft Gear Runout Measurement
c. Measure mainshaft gear runout. Mount gear in lathe or V-blocks and measure runout at specified point. Correct runout is 0.0006 inch.
d. Measure clearance between main shaft and gears where the gear is installed. Measure inside diameter of gear. Difference between two
measurements is clearance. If clearance is more than 0.003 inch, replace gear and/or shaft as necessary.
6. Inspect synchronizer ring as follows:
a. Ensure ring engages smoothly with gear.
b. Inspect teeth for wear or damage and surface for tapering.
c. Measure clearance from side of gear by pressing synchronizer ring uniformly against gear and measuring around circumference. Standard
clearance is 0.059 inch.
7. Inspect clutch hub for worn or damaged splines, synchronizer key groove, or end surface. Check for smooth hub sleeve when it is installed.
8. Inspect clutch hub sleeve for worn or damaged hub splines of sleeve fork groove.
9. Inspect synchronizer keys and springs for worn key and bent springs.
10. Inspect differential for damaged or worn gears and cracked or damaged gear case.
11. Inspect speedometer drive gear assembly for worn or damaged teeth or 0-ring and seal.
12. Inspect reverse idler gear for worn or damaged bushing, gear teeth, or release lever coupling groove. Check for excessive clearance between the
sleeve and the reverse lever. Standard allowable clearance is 0.004-0.013 inch.
