Countershaft Reassembly

Countershaft Reassembly

Countershaft L4-1.8L SOHC:

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 manual transmission fluid (MTF) 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 onto the countershaft.
6. Support the countershaft (A) on steel blocks, then install the 1st/2nd synchro hub (B) with 1st gear (C) using the 40 mm I.D. driver (D), 30 mm I.D. attachment (E), and a press (F).





7. Install the 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 40 mm I.D. driver (C) and a press (D).





11. Install 4th gear (A) using the 40 mm I.D. driver (B) and a press (C).





12. Install 5th gear (A) using the 40 mm I.D. driver (B) and a press (C).





13. Install the distance collar.
14. Install the 32 mm shim and the old ball bearing (A) using the 40 mm I.D. driver (B), 30 mm I.D. attachment (C), 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 15 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.
19. Install the new ball bearing (A) using the 40 mm I.D. driver (B), 30 mm I.D. attachment (C), and a press, then recheck the clearance.





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





21. Tighten the new special bolt (B) (left-hand threads).