M/T Countershaft Disassembly, Reassembly, and Inspection

M/T Countershaft Disassembly, Reassembly, and Inspection









Disassembly

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

1. M/T Change Lever Assembly





1. Remove the change lever assembly (A).

2. Remove the 8 x 10 mm dowel pins (B).

2. Back Up Light Switch





1. Remove the back-up light switch (A) and the 18 mm sealing washer (B).

3. M/T Output Shaft Speed Sensor





1. Remove the output shaft (countershaft) speed sensor (A), the plain washer (B), and the O-ring (C).

4. M/T Transmission Housing Assembly





1. Remove the detent bolts (A), the 12 mm sealing washers (B), the detent ball springs (C), and the steel balls (D).





2. Remove the 8 mm flange bolts in a crisscross pattern in several steps.





3. Remove the 32 mm sealing cap (A).

4. While expanding the 69 mm snap ring (B) on the countershaft ball bearing with snap ring pliers, lift the transmission housing (C).

5. Release the snap ring pliers, and remove the transmission housing.

6. Remove the 14 x 20 mm dowel pins (D).

5. M/T Reverse Shift Fork





1. Remove the reverse shift fork (A).

6. Reverse Idler Gear





1. Remove the reverse idler gear (A) and the reverse idler gear shaft (B).

7. M/T Mainshaft and Countershaft and Shift Fork Assembly





1. Apply a thin layer of tape to the mainshaft splines to protect the seal.

NOTE: Do not apply too much tape as it will damage the oil seal.

2. Remove the mainshaft assembly (A) and the countershaft assembly (B) with the shift fork assembly (C) from the clutch housing (D).

3. Remove the 26 mm washer (E).

4. Remove the 36 mm spring washer (F).

8. M/T Countershaft





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

2. Remove the special bolt (B) (left-hand threads).





3. Support the ball bearing (A) on steel blocks (B).

4. Use a press (C) and an attachment (D) to press the countershaft out of the ball bearing.





5. Remove the 32 mm shim (A).

6. Remove the distance collar (B).





7. Support 4th gear (A) on the bearing separator.

8. Press the countershaft (B) out of 4th gear and 5th gear using an attachment (C) and the press (D).





9. Support 2nd gear (A) on the bearing separator.

10. Press the countershaft (B) out of 2nd gear and 3rd gear using an attachment (C) and the press (D).

Inspection

1. M/T Countershaft Inspection





1. Inspect the gear and bearing contact areas for wear and damage.

2. Measure the countershaft at points A, B, and C. If any part of the countershaft is less than the service limit, replace it.



















3. Inspect the runout by supporting both ends of the countershaft.

4. Rotate the countershaft two complete turns while measuring with a dial gauge. If the runout exceeds the standard, replace the countershaft.








View

1. M/T Countershaft Exploded View

Exploded View





Reassembly

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

1. M/T Countershaft





1. Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.

2. Install the 1st gear distance collar (A).

3. Install the needle bearing (B).

4. Install 1st gear (C).





5. Install the friction damper (A).

6. Install the synchro ring (B).

7. Install the synchro spring (C).





8. Install the 1st/2nd synchro hub (A) by aligning the friction damper fingers (B) with the grooves in the 1st/2nd synchro hub.





9. Install the reverse gear (A) by aligning the slots of the reverse gear and the 1st/2nd synchro hub (B).

NOTE: Make sure to align the slots in the 1st/2nd synchro hub as shown.





10. Install the synchro spring (A).

11. Install the synchro ring (B) by aligning the synchro ring fingers (C) with the 1st/2nd synchro hub grooves (D).

12. Check the operation of the 1st/2nd synchro hub set.





13. Install the friction damper (A) to the 2nd gear distance collar (B).

14. Install the 2nd gear distance collar and the friction damper by aligning the friction damper fingers (C) with the grooves (D) in the 1st/2nd synchro hub.





15. Install the needle bearing (A).

16. Install 2nd gear (B).





17. Support the countershaft (A) on steel block, 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.





18. Press on 4th gear (A) using the 40 mm I.D. driver handle and the press (B).

NOTE: Do not exceed the maximum pressure.





19. Press on 5th gear (A) using the 40 mm I.D. driver handle and the press (B).

NOTE: Do not exceed the maximum pressure.





20. Install the distance collar (A).

21. Install the 32 mm shim (B).





22. Temporarily press on the used ball bearing (A) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and the press.





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







24. If the measured clearance in step 23 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 23 is within the standard, go to next step to replace only the ball bearing with a new one.












25. Support the ball bearing (A) on steel blocks (B).

26. Use the press (C) and an attachment (D) to press the countershaft out of the ball bearing.

27. Remove the 32 mm shim.





28. Install the correct 32 mm shim.

NOTE: If necessary, replace the 32 mm shim with the correct one selected in step 24.

29. Press on a new ball bearing (A) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and the press

NOTE: Make sure the ball bearing is installed in the correct direction.

30. Recheck the clearance.





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

32. Tighten a new special bolt (B) (left-hand threads).

NOTE: Apply new MTF to the bolt threads and flange.

2. M/T Mainshaft and Countershaft and Shift Fork Assembly





1. Install the 36 mm spring washer (A).

NOTE: Be sure to install the spring washer in the direction shown.

2. Install the 26 mm washer (B).

3. Apply a thin layer of tape to the mainshaft splines (C) to protect the seal.

NOTE: Do not apply too much tape as it will damage the oil seal.

4. Install the mainshaft assembly (D) and the countershaft assembly (E) with the shift fork assembly (F), as an assembly.

3. Reverse Idler Gear





1. Install the reverse idler gear (A) and the reverse idler gear shaft (B).

4. M/T Reverse Shift Fork





1. Install the reverse shift fork (A).

5. M/T Transmission Housing Assembly





1. Clean any dirt or oil from the mating surface of the transmission housing and the clutch housing.

2. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009 evenly to the clutch housing mating surface of the transmission housing. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
* If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





3. Install the 14 x 20 mm dowel pins (A).

4. Set the tapered cone ring pawl (B) faces the 5th shift fork (C).

5. Place the transmission housing on the clutch housing, making sure to line up the shafts.

6. While expanding the 69 mm snap ring (D) on the countershaft ball bearing using snap ring pliers, push the transmission housing down to start the countershaft ball bearing through the snap ring.

7. Release the pliers, and push down the housing until it bottoms out and the snap ring snaps in place in the countershaft ball bearing snap ring groove.

NOTE: Install the 32 mm sealing cap (E) after setting in the 69 mm snap ring.





8. Make sure the 69 mm snap ring (A) is securely seated in the groove of the countershaft bearing.

Dimension (1) as installed: 3.3-6.5 mm (0.130-0.256 in)

9. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009 evenly to the threads of the 32 mm sealing cap. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
* If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





10. Install the 8 mm flange bolts finger-tight.





11. Tighten the 8 mm flange bolts in a crisscross pattern in several steps.












12. Install the steel balls, the detent ball springs, and the detent bolts (A) with new 12 mm sealing washers (B).

6. M/T Output Shaft Speed Sensor





1. Install the output shaft (countershaft) speed sensor (A) with a new O-ring (B) and the plain washer (C).

7. Back Up Light Switch





1. Install the back-up light switch (A) with a new 18 mm sealing washer (B).

8. M/T Change Lever Assembly





1. Clean any dirt or oil from the mating surface of the change lever assembly and the transmission housing.

2. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, 08718-0004, or 08718-0009 evenly to the transmission housing mating surface of the change lever assembly. Install the component within 5 minutes of applying the liquid gasket.

NOTE:
* If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes.
* If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply new liquid gasket.





3. Install the 8 x 10 mm dowel pins (A).

4. Install the change lever assembly (B).