Countershaft Reassembly

Countershaft Reassembly

Special Tools Required

- Driver, 40 mm I.D. 07746-0030100
1. Install the 40.5 mm cotters (A), 2nd gear (B), thrust needle bearing (C), needle bearing (D), idler gear (E), thrust needle bearing (F), 61 mm washer (G), 1st gear (H), 4th gear (I), 50.8 mm collar (J), 50.8 mm washer (K), 42.2 mm cotters (L), cotter retainer (M), and snap ring (N) on the countershaft (O). Install the 40.5 mm cotters, idler gear, 1st gear, and 4th gear in the direction shown.

2. Install the thrust washer (P), needle bearing (Q) and 5th gear (R).






3. Slide the reverse selector hub (A) over the countershaft (B), then press it into place using the driver (40 mm I. D.) and the press.
NOTE: Some reverse selector hubs are not press-fitted, and can be installed without using the driver and a press.

4. Install the reverse selector, reverse gear collar, needle bearing, and reverse gear over the reverse selector hub.






5. Install the ball bearing (A) over the countershaft, then press it into place using the driver (40 mm I.D.) and the press.






6. Install the conical spring washer (A) in the direction shown, and install the new locknut (B).






7. Hold the countershaft securely with a wrench and a vise, and tighten the locknut to 167 N-m (17.0 kgf-m, 123 lbf-ft).
NOTE:

- Use a torque wrench to tighten the locknut. Do not use an impact wrench.

- The locknut has left-hand threads.





8. Stake the locknut into its shaft in depth (A) of 0.7-1.3 mm (0.03-0.05 in.) using a 3.5 mm punch (B).