Countershaft Disassembly/Inspection/Reassembly

Disassembly





1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
2. Remove the special bolt (left-hand threads).





3. Support ball bearing (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft out of the ball bearing.
4. Remove the 35 mm shim and distance collar.





5. Support 4th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of 5th gear.





6. Support 2nd gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of 3rd gear.

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 Ball bearing surface (transmission housing side): 30.020 - 30.033 mm (1.1819 - 1.1824 inch)
B Distance collar surface: 39.937 - 39.950 mm (1.5723 - 1.5728 inch)
C Needle bearing surface (clutch housing side): 35.000 - 35.015 mm (1.3780 - 1.3785 inch)
Service Limit:
A: 29.97 mm (1.180 inch)
B: 39.88 mm (1.570 inch)
C: 34.95 mm (1.376 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) maximum
Service Limit: 0.05 mm (0.002 inch)

Reassembly

Special Tools Required
^ Attachment, 42 x 47 mm 07746-0010300 Driver, 40 mm I.D.07746-0030100
^ Attachment, 30 mm 07746-0030300
^ Driver 07749-0010000

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 and needle bearing 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 1st/2nd synchro hub (A) by aligning the synchro cone fingers (B) with the 1st/2nd 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 1st/ 2nd 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 2nd gear (A) by aligning the synchro cone fingers (B) with the 2nd gear grooves (C).





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





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





13. Install 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 (C).





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.





35 mm Shim





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 (C).





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