Countershaft Reassembly

Exploded View - Countershaft Reassembly:

Countershaft Reassembly

Special Tools Required
^ Driver, 56 x 62 mm 070AD-PYZA100
^ Driver, 40 mm I.D. 07746-0030100

NOTE: Refer to the Exploded View as needed during this procedure.

1. Clean all parts in solvent, dry them, and apply lubricant to all contact surfaces.





2. Install the countershaft reverse gear (A), needle bearing (B), and 1st gear (C) onto the countershaft (D).





3. Install the triple cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 1st gear (C), then install the synchro spring (D).





4. Install the 1st/2nd synchro hub (A) by aligning the outer synchro ring fingers (B) with grooves in 1st/2nd synchro hub (C).
5. Install the 1st/2nd synchro sleeve.





6. Install the synchro ring (A).
7. Install the triple cone synchro assembly (B) by aligning the outer synchro ring fingers (C) with the grooves in 1st/2nd synchro hub (D).
8. Install the distance collar and needle bearing.





9. Install the 2nd gear (A) by aligning the synchro cone fingers (B) with the holes in 2nd near (C).





10. Support the countershaft (A) on the steel blocks, then install the 3rd gear (B) using the special tool and a press (C).





11. Install the 4th gear (A) using the special tool and a press (B).





12. Install the 5th gear (A) using the special tool and a press (B).





13. Install the 6th gear (A) using the special tool and a press (B).





14. Install the 35 mm shim (A) and the old ball bearing (B) using the special tool and a press (C).





15. Measure the clearance between the old bearing (A) and the 35 mm shim (B) with a feeler gauge (C).





16. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step 15 is within the standard, replace only the ball bearing.





17. Support the 6th gear (A) on steel blocks (B), then using a press (C) and an attachment (D) to press the countershaft out of the old ball bearing.
18. If necessary, install the 35 mm shim selected in step 16, then recheck the clearance.





19. Install the 6th gear (A) using the special tool and a press (B).





20. Install the 35 mm shim (A) and new bearing (B) using the special tool and a press (C).





21. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).
22. Tighten the new 20 mm special bolt (B) (left-hand threads).