Countershaft Disassembly/Inspection/Reassembly

Disassembly





1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
2. Use a chisel (A) to raise the locknut tab (B) from the groove in the countershaft.





3. Remove the locknut (A) and the spring washer (B).





4. Support 4th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of the ball bearing (F).





5. Remove the friction damper (A) from the spacer (B) using a press (C) and a socket (D).

Inspection





1. Inspect the gear surface and bearing surface for wear and damage, then measure the countershaft at points A, B, and C. If any part of the countershaft is less than the service limit, replace it with a new one.
Standard:
A: 38.000 - 38.015 mm (1.4961 - 1.4967 inch)
B: 39.984 - 40.000 mm (1.5742 - 1.5748 inch)
C: 24.987 - 25.000 mm (0.9837 - 0.9843 inch)
Service Limit:
A: 37.950 mm (1.4941 inch)
B: 39.930 mm (1.5720 inch)
C: 24.940 mm (0.9819 inch)





2. Inspect the runout by supporting both ends of the countershaft. Rotate the countershaft two complete revolutions when measuring the runout. If the runout exceeds the service limit, replace the countershaft with a new one.
Standard: 0.02 mm (0.001 inch) max.
Service Limit: 0.05 mm (0.002 inch)

Reassembly

Special Tools Required
- Driver 07749-0010000
- Attachment, 42 x 47 mm 07746-0010300
- Seal driver 07947-6890100

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

1. Clean all the parts in solvent, dry them, and apply lubricant to all contact surfaces.





2. Install the thrust washer (A) and the needle bearing (B) onto the countershaft (C). Assemble the friction damper (D) and 1st gear (E) together and install them on the countershaft, then install the synchro ring (F) and the synchro spring (G).





3. Install the 1st/2nd synchro hub (A) by aligning the fingers on the friction damper (B) with 1st/2nd synchro hub grooves.
4. Install reverse gear, 2nd gear synchro spring, and the double cone synchro assembly.





5. Install the friction damper (A) on the spacer (B) using the special tools and a press.
6. Install the friction damper and spacer, and the 2nd gear bearing.





7. Install 2nd gear (A) by aligning the synchro cone fingers (B) with 2nd gear grooves (C).
8. Install 3rd gear, 4th gear, and 5th gear.





9. Install the needle bearing (A) and the ball bearing (B) using the special tool and a Dress (C).





10. Install the spring washer (A), and loosely install the new locknut (B).
11. Securely clamp the countershaft assembly in a bench vise with wood blocks.
12. Torque the new locknut to 127 Nm (13 kgf-m, 94 ft. lbs.), then loosen it and torque it again to the same value. Stake the locknut tab into the groove.