Countershaft Reassembly

Countershaft Reassembly

Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 30 mm 07746-0030300

NOTE: Refer to the Exploded View as needed during this procedure.

1. Clean all parts in solvent, dry them, and apply lubricant to all contact surfaces.
2. Install the distance collar, needle bearing, and 1st gear onto the countershaft.





3. Install the triple cone synchro assembly (A) by aligning the synchro cone fingers (B) with 1st gear grooves (C), then install the synchro spring (D).





4. Install the 1sV2nd synchro hub (A) by aligning the synchro cone fingers (B) with 1sV2nd synchro hub grooves (C).
5. Install the reverse gear.





6. Install the synchro spring (A).
7. Install the triple cone synchro assembly (B) by aligning the synchro cone fingers (C) with the 1sV2nd synchro hub grooves (D).





8. Install the distance collar (A) and friction damper (B) by aligning the friction damper fingers (C) with the 1st/2nd synchro hub grooves (D).
9. Install the needle bearing.





10. Install the 2nd gear (A) by aligning the synchro cone fingers (B) with 2nd gear grooves (C).





11. Support the countershaft (A) on the steel blocks, then install the 3rd gear (B) using the special tool and a press (C). Do not exceed the maximum pressure.





12. Install the 4th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.





13. Install the 5th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.





14. Install the distance collar (A), 35 mm shim, and old ball bearing (B) using the special tools and a press





15. Measure the clearance between the old bearing (A) and the 35 mm shim (B) with a feeler gauge (C).
Standard: 0.04 - 0.10 mm (0.002 - 0.004 inch)





16. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step 15 is within the standard, replace only the ball bearing.





17. Support ball bearing (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of the ball bearing.
18. If necessary, install the 35 mm shim selected in step 16, then recheck the clearance.





19. Install the distance collar (A), 35 mm shim, and new ball bearing (B) using the special tools and a press.





20. Tighten the new special bolt (A) (left-hand threads).