Countershaft: Service and Repair
TOOL REQUIRED- 07746-0030100 Driver, 40 mm I.D.
- 07746-0030400 Attachment, 35 mm I.D.
- 07746-0030300 Attachment, 30 mm I.D.
- Or Equivalent
DISASSEMBLE
CAUTION: Remove the gears using a press and steel blocks as shown. Use of a jaw-type puller can damage the gear teeth.
1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
2. Raise the locknut tab from the groove of the countershaft, then remove the locknut and the spring washer.
3. Remove the bearings using a bearing puller as shown.
4. Support 4th gear on steel blocks, and press the countershaft out of 5th and 4th gears as shown.
5. Support 1st gear on steel blocks, and press the countershaft out of 3rd gear as shown.
INSPECTION
1. Inspect the gear surfaces and bearing surfaces for wear and damage, then measure the countershaft at points A, B. and C.
Standard:
A: 30.000 - 30.015 mm (1.1811 - 1.1817 inch)
B: 35.984 - 36.000 mm (1.4167 - 1.4173 inch)
C: 24.980 - 24.993 mm (0.9835 - 0.9840 inch)
Service Limit:
A: 29.950 mm (1.1791 inch)
B: 35.930 mm (1.4146 inch)
C: 24.930 mm (0.9815 inch)
- If any part of the countershaft is less than the service limit, replace it with a new one.
2. Inspect for runout.
- Standard: 0.02 mm (0.001 inch) max.
- Service Limit: 0.05 mm (0.002 inch)
- If the runout is more than the service limit, replace the countershaft with a new one.
ASSEMBLE
CAUTION:
- Press the 3rd,4th, and 5th gears on the countershaft without lubrication.
- When installing the 3rd, 4th, and 5th gears, support the shaft on steel blocks and install the gears using a press.
NOTE: Refer to disassemble for reassembly sequence.
1. Install the needle bearing on the countershaft.
2. Assemble the parts as shown.
NOTE: Check that the fingers of the friction damper are securely set in the grooves of the 1st/2nd synchro hub.
3. Install the parts on the countershaft.
4. Support the countershaft on a steel block as shown and install 3rd gear using the special tools and a press as shown.
5. Install 4th gear using the special tools and a press as shown.
6. Install 5th gear using the special tools and a press as shown.
7. Install the bearings using the special tools and a press as shown.
CAUTION: Install the bearings with a maximum pressure of 7.8 kN (5,786 lbs).
8. Securely clamp the countershaft assembly in a bench vise with wood blocks. Locknut 108 - 0 - 108 Nm (79.6 - 0 - 79.6 ft. lbs.)
9. Install the spring washer, tighten the locknut, then stake the locknut tab into groove.