M/T Countershaft Reassembly

M/T Countershaft Reassembly

Exploded View





Special Tools Required

- Driver Handle, 40 mm I.D. 07746-0030100
- Attachment, 25 mm I.D. 07746-0030200
- Bearing Driver Attachment, 30 mm I.D. 07746-0030300
- Driver,Inner 35mm ID. 07746-0030400

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 distance collar (A), with the needle bearing (B), 1st gear (C), and friction damper (D) on the shaft.





3. Install the 1st gear synchro ring (E) and synchro spring (F) on the shaft.

4. Align the fingers (A) on the friction damper with the grooves (B) on the 1st/2nd synchro hub (C), then install the 1st/2nd synchro hub onto the shaft.






5. Install the reverse gear (A). Install the double cone synchro assembly (B) with the synchro spring (C) by aligning the synchro ring fingers (D) with the 1st/2nd synchro hub grooves (E).






6. Install the distance collar (A) and friction damper (B), then align the fingers (C) on the friction damper and 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 blocks, then press on 3rd gear (B) using the 40 mm inner driver handle (C), 35 mm inner bearing driver attachment (D), and a press (E).

NOTE: Do not exceed the maximum pressure.






9. Press on 4th gear (A) using the 40 mm inner driver handle (B), 30 mm inner bearing driver attachment (C), and a press (D).

NOTE: Do not exceed the maximum pressure.






10. Press on 5th gear (A) using the 40 mm inner driver handle (B), 30 mm inner bearing driver attachment (C), and a press (D).

NOTE: Do not exceed the maximum pressure.






11. Press on the needle bearing (A) using the 40 mm inner driver handle (B), 25 mm inner bearing driver attachment (C), and a press (D).






12. Press on the ball bearing (A) using the 40 mm inner driver handle (B), 25 mm inner bearing driver attachment (C), and a press (D).






13. Install the 22 mm spring washer (A) and a new 22 mm locknut (left-hand threads) (B).






14. Securely clamp the countershaft assembly in a bench vise with wood blocks.

15. Torque the new locknut to 108 Nm (11.0 kg-m, 79.6 lb-ft), then loosen it and torque it again to the same value. Stake the locknut tab into the groove.