Disassembly and Assembly

REMOVAL

1. Remove the mainshaft and countershaft assemblies with the shift forks from the clutch housing.

NOTE: Before removing the mainshaft and countershaft assemblies, tape the mainshaft splines to protect them.

DISASSEMBLE

NOTE: Measure the countershaft gear clearances prior to disassembly. Testing and Inspection

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





2G2. Raise the locknut tab from the groove in the countershaft, then remove the locknut and the spring washer.





3. Remove the ball bearing using a press.





4. Remove the friction damper from the spacer using a press and a socket.

INSPECTION





1. Inspect the gear surface and bearing surface for wear and damage, then measure the countershaft at points A ,B, and C.
- Standard:
A: 38.000 - 38.015 mm (1.4961 -1.4967 inch)
B: 39.984 - 40.000 mm (1.5742 - 1.5748 inch)
C: 24.987 - 25.000 mm (0.9837 - 0.9843 inch)
- Service Limit:
A: 37.950 mm (1.4941 inch)
B: 39.930 mm 11.5720 inch)
C: 24.940 mm (0.9819 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 (0.0008 inch) max.
- Service Limit: 0.05 mm (0.002 inch).

NOTE: Support the countershaft at both ends as shown.

3. Rotate two complete revolutions. If the runout exceeds the service limit, replace the countershaft with a new one.

ASSEMBLE





1. Install the thrust shim, needle bearing, 1st gear, friction damper, synchro ring, and synchro spring.





NOTE: Reassemble the 1st gear and friction damper before installation.





2. Install the 1st/2nd synchro hub by aligning the friction damper fingers with 1st/2nd synchro hub grooves.





3. Install the friction damper on the spacer using the special tools and a press.





4. Install the 2nd gear by aligning the synchro cone fingers with 2nd gear grooves.





5. Install the needle bearing and the ball bearing using a special tool and a press.
6. Securely clamp the countershaft assembly in a bench vise with wood blocks.
7. Install the spring washer.





8. Tighten the new locknut to the correct torque: 127 - O - 127 Nm (34 - 0 - 94 ft. lbs.).

9. Measure the Countershaft gear clearances.

10. If the clearances are within specifications, stake the locknut tab into the groove.