M/T Countershaft Reassembly (5MT)

M/T Countershaft Reassembly

Exploded View





Special Tools Required

- Driver Handle, 40 mm I.D. 07746-0030100
- Bearing Driver Attachment, 30 mm I.D. 07746-0030300

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 1st gear distance collar (A), the needle bearing (B), and 1st gear (C) onto the countershaft (D).






3. Install the friction damper (A), the synchro ring (B), and the synchro spring (C) in 1st gear.






4. Install the 1st/2nd synchro hub (A) by aligning the friction damper fingers (B) with the grooves (C) in the 1st/2nd synchro hub.






5. Install the reverse gear (A), the synchro spring (B), and the synchro ring (C) onto the countershaft. After installing, check the operation of the 1st/2nd synchro hub set.






6. Install the 2st gear distance collar (A) and the friction damper (B) by aligning the friction damper fingers (C) with the 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 block, then press on 3rd gear (B) using the 40 mm I.D. driver handle (C) and a press (D).

NOTE: Do not exceed the maximum pressure.






9. Press on 4th gear (A) using the 40 mm I.D. driver handle (B) and the press (C).

NOTE: Do not exceed the maximum pressure.






10. Press on 5th gear (A) using the 40 mm I.D. driver handle (B) and the press (C).

NOTE: Do not exceed the maximum pressure.





11. Install the distance collar.

12. Install the 32 mm shim, and temporarily press on the used ball bearing (A) using the 40 mm I.D. driver handle (B), the 30 mm I.D. bearing driver attachment (C), and a press.






13. Measure the clearance between the ball bearing (A) and the 32 mm shim (B) with a feeler gauge (C).









14. If the measured clearance in step 13 is not within the standard, select another suitable 32 mm shim from the table, then go to next step to replace the 32 mm shim and the ball bearing with new ones. If the measured clearance in step 13 is within the standard, go to next step to replace only the ball bearing with a new one.

32 mm Shim





15. Remove the ball bearing.

16. Remove the 32 mm shim.

17. Install the correct 32 mm shim, then press on a new ball bearing (A) using the 40 mm I.D. driver handle (B), the 30 mm I.D. bearing driver attachment (C), and a press, then recheck the clearance.

NOTE:

- If necessary, replace the 32 mm shim with the correct one selected in step 14.
- Make sure the ball bearing is installed in the correct direction.





18. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).





19. Tighten a new special bolt (B) (left-hand threads).

NOTE: Apply new MTF to the bolt threads and flange.