Mainshaft/Countershaft

Inspection

NOTE: Lubricate all parts with ATF during assembly.

1. Assemble the parts below on the mainshaft.





NOTE: Do not assemble the O-rings during inspection.





2. Hold the 4th gear collar against the clutch assembly, then measure the clearance between the clutch guide and the 4th gear collar with a feeler gauge as shown.
3. If the clearance is out of tolerance, remove the thrust shim and measure the thickness.





4. Select and install a new shim, then recheck.
5. After replacing the thrust shim, make sure the clearance is within tolerance.

SEALING RINGS
Replacement
The sealing rings on the mainshaft are synthetic resin with chamfered ends. Check the condition of the sealing rings and replace them only if they are worn, distorted, or damaged.

NOTE: Lubricate all parts with ATF during assembly.





1. Squeeze the sealing ring together slightly before installing, for better fit.
2. Install new sealing rings on the mainshaft.





3. After installing the sealing rings, verify the following:
- The sealing rings are fully seated in the groove.
- The sealing rings are not twisted.
- The chamfered ends of the sealing rings are properly joined.

COUNTERSHAFT
Disassembly





1. Remove the reverse selector hub and the 4th gear using a universal two-jaw (or three-jaw) puller as shown.

NOTE:
- Some of the reverse selector hubs are not press fitted and can be removed without using a puller.
- Place a shaft protector between the puller and countershaft to prevent damage to the countershaft.





2. Remove the needle bearing, snap ring, distance collar, and 31 mm cotters from the countershaft.
3. Remove the 1st gear and 3rd gear together from the countershaft using a puller as shown.





NOTE: Place a shaft protector between the puller and countershaft to prevent damage to the countershaft.

Reassembly

NOTE: Lubricate all parts with ATF during assembly.

1. Align the shaft splines with those on 1st gear, then press the countershaft into the 1st gear using a press as shown.

NOTE:
- Place an attachment between the press and countershaft to prevent damage to the countershaft.
- Stop pressing the countershaft when the 1st gear contacts the final drive gear.

2. Align the shaft splines with those on 3rd gear, then press the countershaft into the 3rd gear using a press as shown.





NOTE:
- Place an attachment between the press and countershaft to prevent damage to the countershaft.
- Stop pressing the countershaft when the 3rd gear contacts the 1st gear.

3. Install the 31 mm cotters, distance collar, snap ring, needle bearing, and 4th gear on the countershaft.
4. Install the reverse selector hub on the countershaft, and then press the reverse selector hub using the special tool and a press as shown.





NOTE: Some of the reverse selector hubs are not press-fitted and can be installed without using the special tool and a press.