Countershaft Disassembly, Reassembly, and Inspection
Special Tools Required
Image Description/Tool Number
609749.png Driver, 58 x 62 mm 070AD-PYZA100
310166.png Driver Handle, 40 mm I.D. 07746-0030100

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

1. Countershaft - Disassemble
1.
Securely clamp the countershaft assembly in a bench vise with wood blocks.
2.
Remove the special bolt (left-hand threads).
3.
Support 6th gear (A) on steel blocks, and press the countershaft (B) out of the ball bearing and 6th gear using an attachment (C) and a press (D).
4.
Remove the 35 mm shim.
5.
Support 4th gear (A) on steel blocks, and press the countershaft (B) out of 4th gear and 5th gear using an attachment (C) and a press (D).
6.
Support 2nd gear (A) on steel blocks, and press the countershaft (B) out of 2nd gear and 3rd gear using an attachment (C) and a press (D).

1. Countershaft - Inspect
1.
Inspect the oil passage, gear, and bearing contact areas for wear and damage, then measure the countershaft at points A, B, C, and D. If any part of the countershaft is less than the service limit, replace it.
Standard:
A Ball Bearing Contact Area (Transmission Housing Side):
 
30.002?30.015 mm (1.18118?1.18169 in)
B 2nd Gear Distance Collar Contact Area:
 
42.975?42.991 mm (1.69193?1.69256 in)
C Countershaft Reverse Gear Contact Area:
 
45.934?45.950 mm (1.80842?1.80905 in)
D Needle Bearing Contact Area (Clutch Housing Side):
 
43.974?43.990 mm (1.73126?1.73189 in)
Service Limit:
A:
30.002 mm (1.18118 in)
B:
42.975 mm (1.69193 in)
C:
45.934 mm (1.80842 in)
D:
43.974 mm (1.73126 in)
2.
Inspect the runout by supporting both ends of the countershaft. Then rotate the countershaft two complete turns while measuring with a dial gauge. If the runout exceeds the standard, replace the countershaft.
Standard:
0.02 mm (0.0008 in) max.

1. Countershaft - Exploded View

Exploded View



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

1. Countershaft - Reassemble
1.
Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.
2.
Install the countershaft reverse gear (A).
3.
Install the needle bearing (B).
4.
Install 1st gear (C).
5.
Install the triple cone synchro assembly (A) with the synchro spring (B) by aligning the synchro cone fingers (C) with the holes (D) in 1st gear.
6.
Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 1st/2nd synchro hub.
7.
Install the 1st/2nd synchro sleeve (A) by aligning the slots of the 1st/2nd synchro sleeve and the 1st/2nd synchro hub (B).
NOTE: Make sure to align the slots in the 1st/2nd synchro hub as shown.
8.
Check the operation of the 1st/2nd synchro hub set.
9.
Install the triple cone synchro assembly (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 1st/2nd synchro hub.
10.
Install the 2nd gear distance collar (A) with the needle bearing (B).
11.
Install 2nd gear (A) by aligning the synchro cone fingers (B) with the holes in 2nd gear (C).
12.
Support the countershaft (A) on steel blocks, then press on 3rd gear (B) using the 58 x 62 mm driver and a press (C).
NOTE: Do not exceed the maximum pressure.
13.
Press on 4th gear (A) using the 58 x 62 mm driver and a press (B).
NOTE: Do not exceed the maximum pressure.
14.
Press on 5th gear (A) using the 40 mm I.D. driver handle and a press (B).
NOTE: Do not exceed the maximum pressure.
15.
Press on 6th gear (A) using the 40 mm I.D. driver handle and a press (B).
NOTE: Do not exceed the maximum pressure.
16.
Install the 35 mm shim (A), and temporarily press on the used ball bearing (B) using the 40 mm I.D. driver handle, and a press (C).
NOTE:
Use any size of 35 mm shim, and note size you used. Measurements taken in the following steps will determine the correct shim to use for final assembly.
Make sure the ball bearing is installed in the correct direction.
17.
Measure the clearance between the ball bearing (A) and the 35 mm shim (B) with a feeler gauge (C).
Standard:
0.04?0.10 mm (0.002?0.003 in)
18.
If the measured clearance in step 17 is not within the standard, select another suitable 35 mm shim from the table, then go to next step to replace the 35 mm shim and the ball bearing with new ones. If the measured clearance in step 17 is within the standard, go to the next step to replace only the ball bearing with a new one.
35 mm Shim
Type
Thickness
A
0.87 mm (0.0343 in)
AA
0.91 mm (0.0358 in)
B
0.95 mm (0.0374 in)
AB
0.99 mm (0.0390 in)
C
1.03 mm (0.0406 in)
AC
1.07 mm (0.0421 in)
D
1.11 mm (0.0437 in)
AD
1.15 mm (0.0453 in)
E
1.19 mm (0.0469 in)
AE
1.23 mm (0.0484 in)
F
1.27 mm (0.0500 in)
AF
1.31 mm (0.0516 in)
G
1.35 mm (0.0532 in)
AG
1.39 mm (0.0547 in)
H
1.43 mm (0.0563 in)
AH
1.47 mm (0.0579 in)
J
1.51 mm (0.0594 in)
AJ
1.55 mm (0.0610 in)
K
1.59 mm (0.0626 in)
AK
1.63 mm (0.0642 in)
L
1.67 mm (0.0657 in)
AL
1.71 mm (0.0673 in)
M
1.75 mm (0.0689 in)
AM
1.79 mm (0.0705 in)
N
1.83 mm (0.0720 in)
AN
1.87 mm (0.0736 in)
P
1.91 mm (0.0752 in)
AP
1.95 mm (0.0768 in)
Q
1.99 mm (0.0783 in)
19.
Remove 6th gear with the ball bearing and the 35 mm shim using a press.
20.
Repeat step 15 to install 6th gear.
21.
Install the correct 35 mm shim (A) and a new ball bearing (B) using the 40 mm I.D. driver handle, and a press (C).
NOTE:
If necessary, replace the 35 mm shim with the correct one selected in step 18.
Make sure the ball bearing is installed in the correct direction.
22.
Recheck the clearance between the ball bearing and the 35 mm shim with a feeler gauge.
23.
Securely clamp the countershaft assembly in a bench vise with wood blocks (A).
24.
Tighten a new special bolt (B) (left-hand threads).
NOTE: Apply new MTF to the bolt threads and flange.