Countershaft Disassembly, Reassembly, and Inspection (K20C1 (M/T))

Countershaft Disassembly, Reassembly, and Inspection

Special Tools Required

Image	Description/Tool Number
	Driver Handle, 40 mm I.D. 07746-0030100
	Bearing Driver Attachment, 30 mm I.D. 07746-0030300
	Driver, 58 x 62 mm 070AD-PYZA100

NOTE:

Where icon is shown, click for further information.

	Detailed information, notes, and precautions
	Replace
*1	Triple cone synchro assembly
*2	Left-hand threads

1.	Special Bolt - Remove

Securely clamp the countershaft assembly in a bench vise with wood blocks (A).

Remove the special bolt (B).

2.	Ball Bearing - Remove

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).

NOTE: Do not use a jaw-type puller; it can damage the gear teeth.

3.	35 mm Shim - Remove

4.	6th Gear - Remove

5.	5th Gear - Remove

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

NOTE: Do not use a jaw-type puller; it can damage the gear teeth.

6.	4th Gear - Remove

7.	3rd Gear - Remove

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

NOTE: Do not use a jaw-type puller; it can damage the gear teeth.

8.	2nd Gear - Remove

9.	Needle Bearing - Remove

10.	2nd Gear Distance Collar - Remove

11.	Inner Ring - Remove

12.	Synchro Cone - Remove

13.	Synchro Ring - Remove

14.	Synchro Spring - Remove

15.	1st/2nd Synchro Sleeve - Remove

16.	1st/2nd Synchro Hub - Remove

17.	Synchro Spring - Remove

18.	Synchro Ring - Remove

19.	Synchro Cone - Remove

20.	Inner Ring - Remove

21.	1st Gear - Remove

22.	Needle Bearing - Remove

23.	Counter Shaft Reverse Gear - Remove

1.	Countershaft - Inspect

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.

	Measurement	Standard	Service Limit
A	Ball Bearing Contact Area (Transmission Housing Side)	30.002?30.015 mm (1.18118?1.18169 in)	30.002 mm (1.18118 in)
B	2nd Gear Distance Collar Contact Area	42.975?42.991 mm (1.69193?1.69256 in)	42.975 mm (1.69193 in)
C	Countershaft Reverse Gear Contact Area	45.934?45.950 mm (1.80842?1.80905 in)	45.934 mm (1.80842 in)
D	Needle Bearing Contact Area (Clutch Housing Side)	43.974?43.990 mm (1.73126?1.73189 in)	43.974 mm (1.73126 in)

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.

NOTE:

Where icon is shown, click for further information.

Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.

	Detailed information, notes, and precautions
	Torque: N·m (kgf·m, lbf·ft)
	Replace
*1	Triple cone synchro assembly
*2	Left-hand threads

1.	Counter Shaft Reverse Gear - Install

2.	Needle Bearing - Install

3.	1st Gear - Install

4.	Inner Ring - Install

5.	Synchro Cone - Install

Install the synchro cone (A) by aligning the synchro cone fingers (B) with the holes (C) in 1st gear.

6.	Synchro Ring - Install

Install the synchro ring (A) by aligning the synchro ring fingers (B) with the grooves (C) in the inner ring.

7.	Synchro Spring - Install

8.	1st/2nd Synchro Hub - Install

Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 1st/2nd synchro hub.

NOTE: Make sure to install the 1st/2nd synchro hub in the direction shown.

9.	1st/2nd Synchro Sleeve - Install

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.

Make sure to install the 1st/2nd synchro sleeve in the direction shown.

Check the operation of the 1st/2nd synchro hub set.

10.	Synchro Spring - Install

11.	Synchro Ring - Install

Install the synchro ring (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 1st/2nd synchro hub.

12.	Synchro Cone - Install

13.	Inner Ring - Install

Install the inner ring (A) by aligning the synchro ring fingers (B) with the grooves (C) in the inner ring.

14.	2nd Gear Distance Collar - Install

15.	Needle Bearing - Install

16.	2nd Gear - Install

Install 2nd gear (A) by aligning the synchro cone fingers (B) with the holes in 2nd gear (C).

17.	3rd Gear - Install

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.

18.	4th Gear - Install

Press on 4th gear (A) using the 58 x 62 mm driver and a press (B).

NOTE: Do not exceed the maximum pressure.

19.	5th Gear - Install

Press on 5th gear (A) using the 40 mm I.D. driver handle and a press (B).

NOTE: Do not exceed the maximum pressure.

20.	6th Gear - Install

Press on 6th gear (A) using the 40 mm I.D. driver handle and a press (B).

NOTE: Do not exceed the maximum pressure.

21.	35 mm Shim - Clearance Check

Install the 35 mm shim (A), and temporarily press on the used ball bearing (B) until it bottoms in the direction shown using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, 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.

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)

If the measured clearance 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 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 (0.0531 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)

Remove 6th gear with the ball bearing and the 35 mm shim using a press.

Repeat step 20 (6th Gear - Install).

22.	35 mm Shim - Install

23.	Ball Bearing - Install

Install the ball bearing (A) until it bottoms in the direction shown using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and a press (B).

NOTE: If necessary, replace the 35 mm shim with the correct one selected in step 21-2 (35 mm Shim - Clearance Check).

Recheck the clearance between the ball bearing and the 35 mm shim with a feeler gauge.

24.	Special Bolt - Install

Securely clamp the countershaft assembly in a bench vise with wood blocks (A).

Tighten a special bolt (B).