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
Bearing Separator 07KAF-PS30200
1.
Countershaft - Exploded View
Exploded View
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 the bearing separator, and press the countershaft out of the ball bearing (B), the 32 mm shim, and 6th gear using an attachment (C) and a press (D).
4.
Support 4th gear (A) on the bearing separator, and press the countershaft (B) out of 4th gear and 5th gear using an attachment (C) and a press (D).
5.
Support 2nd gear (A) on the bearing separator, 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, and C. If any part of the countershaft is less than the service limit, replace it.
Standard:
A
Ball Bearing Contact Area
(Transmission Housing Side):
26.020?26.033 mm (1.02441?1.02492 in)
B
1st Gear Distance Collar Contact Area:
38.987?39.000 mm (1.53492?1.53543 in)
C
Needle Bearing Contact Area
(Clutch Housing Side):
34.000?34.015 mm (1.33858?1.33917 in)
Service Limit:
A:
26.020 mm (1.02441 in)
B:
38.987 mm (1.53492 in)
C:
34.000 mm (1.33858 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.
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 1st gear distance collar (A) with the needle bearing (B) and 1st gear (C) on the countershaft (D).
3.
Install the friction damper (A), the synchro ring (B), and the synchro spring (C) on 1st gear (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 countershaft.
5.
Install the reverse gear (A) by aligning the slots of the reverse gear and the 1st/2nd synchro hub (B). After installing, check the operation of the 1st/2nd synchro hub set.
NOTE: Make sure to align the slots in the 1st/2nd synchro hub as shown.
6.
Install the synchro ring (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the 1st/2nd synchro hub grooves (D).
7.
Install the 2nd gear distance collar (A) with the friction damper (B), then align the fingers (C) on the friction damper and the grooves (D) in the 1st/2nd synchro hub.
8.
Install the needle bearing (A).
9.
Install 2nd gear (B).
10.
Support the countershaft (A) on steel blocks, then press on 3rd gear (B) using the 40 mm I.D. driver handle and a press (C).
NOTE: Do not exceed the maximum pressure.
11.
Press on 4th gear (A) using the 40 mm I.D. driver handle and a press (B).
NOTE: Do not exceed the maximum pressure.
12.
Press on 5th gear (A) using the 40 mm I.D. driver handle and a press (B).
NOTE: Do not exceed the maximum pressure.
13.
Press on 6th gear (A) using the 40 mm I.D. driver handle and a press (B).
NOTE: Do not exceed the maximum pressure.
14.
Install the 32 mm shim (A), and temporarily press on the used ball bearing (B) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment , and a press (C).
Use any size of the 32 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.
15.
Measure the clearance between the bearing (A) and the 32 mm shim (B) with a feeler gauge (C).
Standard:
0.01?0.10 mm (0.001?0.003 in)
16.
If the measured clearance in step 15 is not within the standard, select another suitable 32 mm shim from the table, then go to next step to replace the 32 mm shim and the ball bearing with new ones. If the measured clearance in step 15 is within the standard, go to the next step to replace only the ball bearing with a new one.
32 mm shim:
Type
Thickness
A
1.56 mm (0.0614 in)
B
1.60 mm (0.0630 in)
C
1.64 mm (0.0646 in)
D
1.68 mm (0.0661 in)
E
1.72 mm (0.0677 in)
F
1.76 mm (0.0693 in)
G
1.80 mm (0.0709 in)
H
1.84 mm (0.0724 in)
J
1.88 mm (0.0740 in)
K
1.92 mm (0.0756 in)
L
1.96 mm (0.0772 in)
M
2.00 mm (0.0787 in)
N
2.04 mm (0.0803 in)
P
2.08 mm (0.0819 in)
Q
2.12 mm (0.0835 in)
R
2.16 mm (0.0850 in)
S
2.20 mm (0.0866 in)
T
2.24 mm (0.0882 in)
U
2.28 mm (0.0898 in)
V
2.32 mm (0.0913 in)
17.
Remove 6th gear with the ball bearing and the 32 mm shim using a press.
18.
Repeat step 13 to install 6th gear.
19.
Install the correct 32 mm shim (A) and a new ball bearing (B) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and a press (C).
NOTE:
If necessary, replace the 32 mm shim with the correct one selected in step 16.
Make sure the ball bearing is installed in the correct direction.
20.
Recheck the clearance between the ball bearing and the 32 mm shim with a feeler gauge.
21.
Securely clamp the countershaft assembly in a bench vise with wood blocks (A).
22.
Tighten a new special bolt (B) (left-hand threads).
