Countershaft Reassembly

Countershaft Reassembly

Special Tools Required
^ Driver, 40 mm I.D.7746-0030100
^ Attachment, 25 mm I.D.7746-0030200
^ Attachment, 30 mm I.D.7746-0030300
^ Attachment, 35 mm I.D.7746-0030400

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

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





2. Install the needle bearing (A), 1st gear (B), and friction damper (C) on the shaft.





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





4. Align the fingers (A) on the friction damper with the grooves (B) on the 1st/2nd synchro hub (C), then install the 1st/2nd synchro hub onto the shaft.
5. Install the reverse gear.





6. Install the synchro spring (A).
7. Install the double cone synchro assembly (B) by aligning the synchro ring fingers (C) with the 1st/ 2nd synchro hub grooves (D).





8. Install the distance collar (A) and friction damper (B), then align the fingers (C) on the friction damper and grooves (D) in the 1st/2nd synchro hub.





9. Install the needle bearing (A).
10. Install 2nd gear (B) by aligning the 2nd gear holes (C) with synchro cone fingers (D).





11. Install 3rd gear (A) using the special tools and a press (B).





12. Install 4th gear (A) using the special tools and a press (B).





13. Install 5th gear (A) using the special tools and a press (B).





14. Install the needle bearing (A) using the special tools and a press (B).





15. Install the ball bearing (A) using the special tools and a press (B).





16. Install the 22 mm spring washer (A) and 22 mm locknut (left-hand threads) (B).
17. Securely clamp the countershaft assembly in a bench vise with wood blocks.
18. Torque the new locknut to 108 Nm (11.0 kgf-cm, 79.6 ft. lbs.), then loosen it and torque it again to the same value. Stake the locknut tab into the groove.