Countershaft: Service and Repair

REMOVAL
1. Remove the interlock guide bolt from under the clutch housing.





2. Remove the shift arm B attaching bolt.





3. Remove the mainshaft and countershaft assemblies with the shift fork from the clutch housing.

NOTE: Before removing the mainshaft and countershaft assemblies, tape the mainshaft spline to protect it.

DISASSEMBLE

CAUTION: Remove the gears using a press and steel blocks as shown. Use of a jaw-type puller can damage the gear teeth.

1. Securely clamp the countershaft assembly in a bench vise with wood blocks.





2. Raise the locknut tab from the groove of the countershaft, then remove the locknut and the spring washer.





3. Remove the bearings using a bearing puller as shown.





4. Support 4th gear on steel blocks as shown and press the countershaft out of 5th and 4th gears.





5. Support 1st gear on steel blocks as shown and press the countershaft out of 3rd gear.

INSPECTION
Inspect the coutnershaft Testing and Inspection .

ASSEMBLE

CAUTION:
- Press the 3rd,4th. and 5th gears on the countershaft without lubrication.
- When installing the 3rd, 4th, and 5th gears, support the shaft on steel blocks and install the gears using a press.





1. Install the needle bearing on the countershaft.





2. Assemble the parts below as shown.

NOTE: Check that the fingers of the friction damper are securely set in the grooves of the 1st/2nd synchro hub.

3. Install the parts on the countershaft.





4. Support the countershaft on a steel block as shown and install 3rd gear using the special tools and a press as shown.





5. Install 4th gear using the special tools and a press as shown.





6. Install 5th gear using the special tools and a press as shown.





7. Install the bearings using the special tools and a press as shown.
8. Securely clamp the countershaft assembly in a bench vise with wood blocks.





9. Install the spring washer, tighten the locknut, then stake the locknut tab into groove. Locknut 110 - 0 - 110 Nm (80 - 0 - 80 ft. lbs.)