Countershaft Reassembly

Countershaft Reassembly

Countershaft:

Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 25 mm I.D. 07746-0030200
^ Attachment, 30 mm I.D. 07746-0030300
^ Attachment, 35 mm I.D. 07746-0030400

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

1. Clean all the parts in solvent, dry them, and apply lubricant all contact surfaces.
2. Install the needle bearing (A), 1st gear (B), and friction damper (C) on the countershaft (D).





3. Install the 1st gear synchro ring (E) and synchro spring (F) on the countershaft.
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), synchro spring (B), and synchro ring (C) on the countershaft.





6. Install the distance collar (A) and friction damper (B), then align the fingers (C) on the friction damper and grooves (D) in the 1st/2nd synchro hub.





7. Install the needle bearing (A) and 2nd gear (B).





8. Install the 3rd gear (A) using the 40 mm I.D. driver (B), 35 mm I.D. attachment (C), and a press (D).





9. Install the 4th gear (A) using the 40 mm I.D. driver (B), 30 mm I.D. attachment (C), and a press (D).





10. Install the 5th gear (A) using the 40 mm I.D. driver (B), 30 mm I.D. attachment (C), and a press (D).





11. Install the needle bearing (A) using the 40 mm I.D. driver (B), 25 mm I.D. attachment (C), and a press (D).





12. Install the ball bearing (A) using the 40 mm I.D. driver (B), 25 mm I.D. attachment (C), and a press (D).





13. Securely clamp the countershaft assembly in a bench vise with wood blocks.
14. Install the 22 mm spring washer (A) and new 22 mm locknut (left-hand threads) (B).





15. Torque the new 22 mm locknut to 108 Nm (11.0 kgf-m, 79.6 lbf-ft), then loosen it and torque it again to the same value. Stake the locknut tab into the groove.