Countershaft Disassembly, Reassembly, and Inspection
Special Tools Required
Image Description/Tool Number
310166.png Driver Handle, 40 mm I.D. 07746-0030100
1. Countershaft - Exploded View

Exploded View



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

1. Countershaft - Disassemble
1.
Secure the final drive gear part of the countershaft in a bench vise with wood blocks.
2.
Remove the lock bolt (A).
NOTE:
The lock bolt has left-hand threads.
After this procedure, remove wood chips that may be stuck to the gear.
3.
Place the park gear (A) on press bases (B).
4.
Place a spacer (C) between the countershaft (D) and a press to prevent damaging the countershaft.
5.
Remove these parts in the following order using the press:
-1.
Ball bearing (A)
-2.
2nd gear (B)
-3.
42.5 mm thrust shim (C)
-4.
5th gear collar (D)
-5.
42.5 x 52.5 x 2.5 mm thrust washer (E)
-6.
5th gear (F)
-7.
1st gear (G)
-8.
53 x 57 x 20 mm needle bearing (H)
-9.
Park gear (I)

1. Countershaft - Inspect
1.
Inspect the bearing for galling and rough movement.
2.
Inspect the shaft bearing surfaces for scoring and excessive wear.
3.
Inspect the shaft splines for excessive wear and damage.

2. Countershaft 2nd Gear and 5th Gear Axial Clearance - Inspect

Inspect the countershaft 2nd gear axial clearance and the 5th gear axial clearance.

3. 1st Gear One-Way Clutch - Inspect

Inspect the 1st gear one-way clutch.


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

1. Countershaft - Reassemble
1.
Place the park gear (A).
2.
Place the park gear (A) on press bases (B).
3.
Place a spacer (C) between the countershaft (D) and a press to prevent damaging the countershaft.
4.
Install the park gear using the press.
5.
Install these parts in the following order as shown:
-1.
53 x 57 x 20 mm needle bearing (A)
-2.
1st gear (B)
-3.
5th gear (C)
-4.
42.5 x 52.5 x 2.5 mm thrust washer (D)
-5.
5th gear collar (E)
-6.
Selected 42.5 mm thrust shim (F)
-7.
2nd gear (G)
6.
Install the ball bearing (A).
7.
Press the ball bearing into place using the 40 mm I.D. driver handle and the press.
8.
Secure the final drive gear part of the countershaft in a bench vise with wood blocks.
9.
Install a new lock bolt (A) to 125 N·m (12.7 kgf·m, 92 lbf·ft).
NOTE:
The lock bolt has left-hand threads.
After this procedure, remove wood chips that may be stuck to the gear.