20. Countershaft Reassembly

Countershaft Reassembly

Countershaft:

Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 30 mm I.D. 07746-0030300

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

1. Clean all parts in solvent, dry them, and apply lubricant to all contact surfaces.
2. Install the distance collar and the needle bearing onto the countershaft.





3. Install the 1st gear synchro ring (A), synchro spring (B) and the friction damper (C) on the 1st/2nd synchro hub (D).
4. Align the fingers (E) on the friction damper with the grooves (F) on the 1st/2nd synchro hub, then install the 1st gear (G) onto the 1st/2nd synchro hub.
5. Supporting by hand, turn the 1st/2nd synchro hub side upward, then install the 1st/2nd synchro hub with 1st gear on to the counter shaft.





6. Support the countershaft (A) on steel blocks, then install the 1st/2nd synchro hub (B) with 1st gear (C) using the special tool and a press (D). Do not exceed the maximum pressure.
7. Install reverse gear, the synchro spring, and the synchro ring on the shaft.





8. Install the distance collar (A) and friction damper (B), by aligning the friction damper fingers (C) with the 1st/2nd synchro hub grooves (D).
9. Install the needle bearing and 2nd gear.





10. Support the countershaft (A) on steel blocks, then install 3rd gear (B) using the special tool and a press (C). Do not exceed the maximum pressure.





11. Install 4th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.





12. Install 5th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.
13. Install the distance collar.





14. Install the 32 mm shim and the old ball bearing (A) using the special tools and a press.





15. Measure the clearance between the old bearing (A) and the 32 mm shim (B) with a feeler gauge (C).





16. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step 18 is within the standard, replace only the new ball bearing.





17. Support ball bearing (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft out of the ball bearing.
18. If necessary, install the 32 mm shim selected in step 16, then recheck the clearance.





19. Install the new ball bearing (A) using the special tools and a press (B).





20. Tighten the new special bolt (A) (left-hand threads).