Countershaft: Service and Repair

COMPONENTS

DISASSEMBLY OF COUNTER SHAFT

1. REMOVE UNDERDRIVE PLANETARY SUN GEAR FROM COUNTER SHAFT

2. MEASURE STARTING TORQUE OF COUNTER SHAFT

a. Using SST, temporarily tighten the lock nut.
SST 09350 - 32014 (09351 - 32170)

b. Using soft jaws, hold the drive pinion in a vise.
c. Using SST and spring tension gauge, measure the starting torque of the counter shaft.
SST 09350 - 32014 (09351 - 32170)

Starting torque:
with spring tension gauge 1.2 - 2.0 kg (2.6 - 4.4 lb)
with torque gauge (hexagon nut side) 6 - 10 kg-cm (5.2 - 8.7 in.lb 0.6 - 1.0 N.m)

If the torque is exceeded, replace the spacer.

d. Using SST, remove the lock nut.
SST 09350 - 32014 (09351 - 32170)

3. REMOVE SNAP RING FROM SUN GEAR
Using snap ring pliers, remove the snap ring from the sun gear.

4. REMOVE SNAP RING FROM COUNTER SHAFT ASSEMBLY
Using a screwdriver, remove the snap ring from the counter shaft assembly.

5. REMOVE UNDERDRIVE PLANETARY GEAR

6. REMOVE THRUST NEEDLE ROLLER BEARING AND RACE

7. REMOVE DRIVE PINION WITH OUTPUT FLANGE, BEARING, INNER RACE AND SPACER

a. Using SST and press, remove the drive pinion with output flange, bearing and inner race.
SST 09350 - 32014 (09351 - 32150, 09351 - 32130), 09555 - 55010

b. Remove the spacer from the counter shaft.

8. REMOVE RING GEAR

a. Using a screwdriver, remove the snap ring from the counter shaft.

b. Remove the ring gear from the counter shaft.

9. REMOVE BEARING
Using SST and press, remove the bearing.
SST 09950 - 00020

10. REMOVE BEARING OUTER RACES
Using a brass bar and hammer, tap out both bearing outer races.

INSPECTION OF COUNTER SHAFT COMPONENTS

1. MEASURE PLANETARY SUN GEAR BUSHING INSIDE DIAMETER
Using a caliper gauge, measure the bushing inside diameter of the planetary sun gear as shown.

Standard inside diameter: 29.800 - 29.825 mm (1.17322 - 1.17421 in.)
Maximum inside diameter: 29.870 mm (1.17598 in.)

2. MEASURE PLANETARY PINION GEAR THRUST CLEARANCE
Using a feeler gauge, measure the planetary pinion gear thrust clearance.

Standard clearance: 0.2 - 0.5 mm (0.008 - 0.020 in.)
Maximum clearance: 0.5 mm (0.020 in.)

If the clearance is greater than the maximum, replace the planetary gear assembly.

ASSEMBLY OF COUNTER SHAFT

1. IN STALL BEARING TO COUNTER SHAFT
Using SST and press, press in the bearing of the thick inner race side.
SST 09350 - 32014 (09351 - 32180)

2. INSTALL RING GEAR
a. Install the ring gear to the counter shaft.

b. Install the snap ring.

3. INSTALL BEARING OUTER RACES TO DRIVE PINION

a. Using SST and press, press in the thick race to the flange side of the drive pinion.
SST 09350 - 32014 (09351 - 32090, 09351 - 32180)

b. Using SST and press, press in the thin race to the other side.
SST 09350 - 32014 (09351 - 32150, 09351 - 32180)

4. INSTALL DRIVE PINION TO COUNTER SHAFT

a. Install the new spacer to the counter shaft.

b. Install the drive pinion to the counter shaft.

5. INSTALL ANOTHER BEARING TO COUNTER SHAFT
Using SST and press, press in the another bearing.
SST 09350 - 32014 (09351 - 32180)

CAUTION: Be sure there is some clearance between the output flange and bearing.

6. INSTALL BEARING INNER RACE
Using SST and press, press in the inner race.
SST 09350 - 32014 (09351 - 32180)

CAUTION: Be sure there is some clearance.

7. ADJUST COUNTER SHAFT STARTING TORQUE

a. Using SST and press, press in the counter driven gear to the counter shaft.
SST 09350 - 32014 (09351 - 32100)

b. Install SST to the driven gear.
SST 09350 - 32014 (09351 - 32031)

c. Secure the counter shaft by holding the SST in a vise.
SST 09350 - 32014 (09351 - 32031)

d. Temporarily install the new lock nut, and using SST, tighten the lock nut until the counter shaft starting torque is in specification.
SST 09350 - 32014 (09351 - 32170)

Torque (Reference): 1,610 - 1,970 kg-cm (116 - 142 ft-lb, 157 - 193 N.m)

NOTE: Use a torque wrench with a fulcrum length of 42 cm (16.54 in.).

e. Using soft jaws, hold the drive pinion in a vise.
f. Using SST and spring tension gauge, measure the starting torque of the counter shaft.
SST 09350 - 32013 (09351 - 32170)

Starting torque:
with tension gauge 1.2 - 2.0 kg (2.6 - 4.4 lb)
with torque gauge (hexagon nut side) 6 - 10 kg-cm (5.2 - 8.7 in-lb, 0.6 - 1.0 N.m)

If the starting torque is exceeded, replace the spacer and retorque.

NOTE: Before measuring the starting torque, snug down the bearing by turning the counter shaft.