M/T Countershaft Reassembly

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) with the needle bearing (B) and 1st gear (C) on the countershaft (D).






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






4. Align the fingers (A) on the friction damper with the grooves (B) on the 1st/2nd synchro hub (C), then install the 1st/2nd synchro hub onto the countershaft.






5. Install the reverse gear (A) by aligning the slots of the reverse gear and the 1st/2nd synchro hub (B). After installing, check the operation of the 1st/2nd synchro hub set Synchro Sleeve And Hub Inspection And Reassembly.

NOTE: Make sure to align the slots in the 1st/2nd synchro hub as shown.






6. Install the double cone synchro assembly (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the 1st/2nd synchro hub grooves (D).






7. Install the 2nd gear distance collar (A) with the friction damper (B), then align the fingers (C) on the friction damper and the grooves (D) in the 1st/2nd synchro hub.






8. Install the needle bearing (A), then install 2nd gear (B) by aligning the synchro cone fingers (C) with the grooves (D) in 2nd gear.






9. Support the countershaft (A) on steel blocks, then press on 3rd gear (B) using the 40 mm driver handle (C) and a press (D).

NOTE: Do not exceed the maximum pressure.






10. Press on 4th gear (A) using the 40 mm driver handle (B) and a press (C).

NOTE: Do not exceed the maximum pressure.






11. Press on 5th gear (A) using the 40 mm driver handle (B) and a press (C).

NOTE: Do not exceed the maximum pressure.






12. Press on 6th gear (A) using the 40 mm driver handle (B) and a press (C).

NOTE: Do not exceed the maximum pressure.






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

- Use any size of the 32 mm shim, and note size you used. Measurements taken in the following steps will determine the correct shim to use for final assembly.
- Make sure the ball bearing is installed in the correct direction.





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










15. If the measured clearance in step 14 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 14 is within the standard, go to the next step to replace only the ball bearing with a new one.

32 mm Shim





16. Remove 6th gear with the ball bearing and the 32 mm shim using a press.

17. Repeat step 12 to install 6th gear.

18. Install the correct 32 mm shim (A) and a new ball bearing (B) using the 40 mm driver handle (C), the 30 mm bearing driver attachment (D), and a press (E).

NOTE:

- If necessary, replace the 32 mm shim with the correct one selected in step 15.
- Make sure the ball bearing is installed in the correct direction.





19. Recheck the clearance between the bearing and the 32 mm shim with a feeler gauge.

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





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

NOTE: Apply MTF to the bolt threads and flange.