COUNTERSHAFT COMPONENT ASSEMBLY

BHE051117050104

1. Assemble in the order indicated in the table.

2. Verify the following after assembly.

(1) The gear rotates smoothly when rotated by hand.
(2) The synchronizer ring is not stuck.

1
Clutch hub
2
Synchronizer key
3
Synchronizer key spring
4
Steel ball
5
Clutch hub sleeve
6
Countershaft gear
7
Needle bearing
8
Counter 3rd gear
9
Inner ring
10
Middle ring
11
Synchronizer ring
12
Clutch hub component (3rd/4th)
13
Synchronizer ring
14
Counter 4th gear
15
Inner race
16
Thrust washer
17
Retaining ring
18
Snap ring
19
Counter drive gear
20
Snap ring (friction gear)
21
Torsion spring
22
Friction gear
23
Snap ring
24
Roller bearing
25
Snap ring (roller bearing)

Clutch Hub Component (3rd/4th) Assembly Note

1. Securely align the tabs on each ring of the 3rd gear side with the installation hole of the 3rd gear and the key groove of the clutch hub.

2. Securely align the tab on the synchronizer ring of 4th gear side with the key groove of the clutch hub.

Caution
• Do not damage the synchronizer ring when installing the clutch hub component.

3. Carefully install the clutch hub component (3rd/4th) using the SSTs and a press.

Thrust Washer Assembly Note

1. Install the thrust washer removed during disassembly, and measure the clearance between the thrust washer and the installation groove using a feeler gauge.

2. Select the new thrust washer from the following table so that the clearance measured in Step 1 is within specification, and install it in the countershaft gear with the identification mark facing up.

Clearance
0-0.1 mm {0-0.0039 in}

Thrust washer size

mm {in}

Identification mark

Thickness

Identification mark

Thickness

A
3.75 {0.148}
E
3.95 {0.156}
B
3.80 {0.150}
F
4.00 {0.157}
C
3.85 {0.152}
G
4.05 {0.159}
D
3.90 {0.154}
H
4.10 {0.161}

Counter Drive Gear Assembly Note

1. Install the counter drive gear using the SSTs.

Snap Ring (Friction Gear) Assembly Note

1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge.

2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the countershaft gear.

Clearance
0-0.1 mm {0-0.0039 in}

Snap ring size

mm {in}

Identification mark

Thickness

Identification mark

Thickness

A
1.80 {0.071}
D
1.95 {0.077}
B
1.85 {0.073}
E
2.00 {0.079}
C
1.90 {0.075}
F
2.05 {0.081}

Roller Bearing Assembly Note

1. Install the roller bearing using the SSTs.

Snap Ring (Roller Bearing) Assembly Note

1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge.

2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the countershaft gear.

Clearance
0-0.1 mm {0-0.0039 in}

Snap ring size

mm {in}

Identification mark

Thickness

Identification mark

Thickness

A
3.75 {0.148}
E
3.95 {0.156}
B
3.80 {0.150}
F
4.00 {0.157}
C
3.85 {0.152}
G
4.05 {0.159}
D
3.90 {0.154}
H
4.10 {0.161}