Countershaft Reassembly

Countershaft Reassembly





2000-2003 models





2004 - 2005 model

Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ 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. Install the 44 x 50 x 28 mm needle bearing and 2nd gear.





2. Install the friction damper (A), the double cone synchro (B), and the synchro spring (C) as shown.





3. Install the 1st/2nd synchro hub (A) and the sleeve (B) as shown.





4. Install the synchro spring (A) and the double cone synchro (B) as shown.





5. Install the friction damper (2000-2003 models) on 1st gear, then install 1st gear by aligning the grooves as shown.
6. Install the 51 x 57 x 23 mm needle bearing, distance collar, and 38 x 43 x 26 mm needle bearing.





7. Install the reverse sear
8. Install the synchro ring and synchro spring.





9. Install the reverse synchro hub (A) and the sleeve (B).





10. Install the ball bearing (A) using the special tools and a press as shown.





11. Securely clamp 4th and 5th gears in a bench vise with wood blocks (A).
12. Install the spring washer (B) and the 27 mm locknut (C).
13. Tighten the 27 mm locknut to the specified value.
Torque: 162 -> 0 -> 162 Nm (16.5 -> 0 -> 16.5 kgf-cm, 119 -> 0 -> 119 ft. lbs.)





14. Stake the locknut tab into the groove.





15. Install the needle bearing inner race (A) using the special tools and a press as shown.





16. Install the needle bearing.