M/T Countershaft Reassembly

M/T Countershaft Reassembly

Exploded View '00-03 models





Exploded View '04-09 models





Special Tools Required

- Inner driver handle, 40 mm 07746-0030100
- Inner bearing driver attachment, 30 mm 07746-0030300
- Inner bearing driver attachment, 35 mm 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 1st/2nd synchro sleeve (B) as shown.






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






5. Install the friction damper ('00-03 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, the 1st/reverse gear distance collar, and the 38 x 43 x 26 mm needle bearing.






7. Install reverse gear.

8. Install the synchro ring and the synchro spring.






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






10. Press on the ball bearing (A) using the 40 mm inner driver handle (B), the 30 mm inner bearing driver attachment (C), 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 a new 27 mm locknut (C).

13. Tighten the 27 mm locknut to the specified value.










14. Stake the locknut tab into the groove.






15. Press on the needle bearing inner race (A) using the 40 mm inner driver handle (B), the 35 mm inner bearing driver attachment (C), and a press as shown.






16. Install the needle bearing.