Countershaft: Service and Repair

REMOVAL
1. Remove the mainshaft and the countershaft assemblies with the shift forks from the clutch housing.

NOTE: Tape the mainshaft spline before removing the mainshaft and the countershaft assemblies.





2. Remove the spring washer and the washer.





3. Remove the differential assembly from the clutch housing.





4. Remove the chamber plate.

DISASSEMBLE
1. Securely clamp the countershaft assembly in a bench vise with wood blocks.





2. Raise the locknut tab from the groove in the countershaft, then remove the locknut and the spring washer.





3. Remove the ball bearing using a bearing puller as shown.





4. Remove the bearing outer race, then remove the needle bearing using a bearing puller as shown.

CAUTION: Remove the gears using a press and the steel blocks as shown. Use of a jaw-type puller can cause damage to the gear teeth.





5. Support 4th gear on steel blocks, and press the countershaft out of 5th and 4th gears, as shown.

INSPECTION
Inspect the countershaft Testing and Inspection.

ASSEMBLE

CAUTION:
- Press 4th and 5th gears on the countershaft without lubrication.
- When installing 4th and 5th gears, support the shaft on steel blocks, and install the gears using a press.
- Install 4th and 5th gear with a maximum pressure of 25.5 kN (18,806 lbs.).





1. Install the thrust shim and the needle bearings on the countershaft.
2. Install the friction damper, the synchro ring, and the synchro spring on 1st gear.





3. Install the 1st/2nd synchro hub by aligning the fingers on the friction damper and the grooves in the 1st/2nd synchro hub, as shown.
4. Install the reverse gear.





5. Install the synchro spring and the double cone synchro as shown.
6. Assemble the friction damper, the needle bearing, and 2nd gear, then install them by aligning the fingers on the friction damper and the grooves in the 1st/2nd synchro hub with the fingers of the double cone synchro and the grooves on 2nd gear, as shown.





7. Install the spacer.
8. Install the parts assembled in steps 2 - 6 on the countershaft.





9. Support the countershaft on a steel block, and install 4th gear using the special tools and a press,





10. Support the countershaft on a steel block, and install 5th gear using the special tools and a press, as shown.





11. Install the needle bearing, then install the ball bearing using the special tools and a press as shown.
12. Securely clamp the countershaft assembly in a bench vise with wood blocks.





13. Install the spring washer, tighten the locknut, then stake the locknut tab into the groove. Lock nut: 108-0-108 Nm (80-0-80 ft. lbs.)