M/T Countershaft Reassembly

M/T Countershaft Reassembly

Exploded View





Special Tools Required

- Inner driver handle, 40 mm 07746-0030100
- Inner bearing driver attachment, 30 mm 07746-0030300

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

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

2. Install the 1st gear distance collar (A) with the needle bearing (B) and 1st gear (C) onto the countershaft (D).






3. Install the friction damper (A), the synchro ring (B), and the synchro spring (C) in 1st gear.






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






5. Install the reverse gear (A), the synchro spring (B), and the synchro ring (C) onto the countershaft. After installing, check the operation of the 1st/2nd synchro hub set.






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






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






8. Support the countershaft (A) on steel block, then install 3rd gear (B) using the 40 mm inner driver handle (C) and a press (D).
NOTE: Do not exceed the maximum pressure.






9. Install 4th gear (A) using the 40 mm inner driver handle (B) and a press (C).
NOTE: Do not exceed the maximum pressure.






10. Install 5th gear (A) using the 40 mm inner driver handle (B) and a press (C).
NOTE: Do not exceed the maximum pressure.

11. Install the 5th gear distance collar.






12. Install the 32 mm shim, and temporary press on the old ball bearing (A) using the 40 mm inner driver handle (B), the 30 mm inner bearing driver attachment (C), and a press.






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





14. If the measured clearance in step 13 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. If the measured clearance in step 13 is within the standard, go to next step to replace only the ball bearing.

32 mm Shim





15. Remove the ball bearing. M/T Countershaft Disassembly

16. Remove the 32 mm shim.






17. Install the correct 32 mm shim, then press on new ball bearing (A) using the 40 mm inner driver handle (B), the 30 mm inner bearing driver attachment (C), and a press, then recheck the clearance.
NOTE:

- If necessary, replace the 32 mm shim with the correct one selected in step 14.

- Make sure to install the ball bearing as shown.





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

19. Tighten the new special bolt (B) (left-hand threads).
NOTE: Apply MTF to the bolt threads and flange.