Countershaft Disassembly/Inspection/Reassembly

Exploded View





5-speed model





6-speed model

Disassembly

NOTE: 6-speed model is shown, 5-speed model is similar.





1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
2. Remove the special bolt (left-hand threads).





3. Support ball bearing (A) (5-speed model) or 6th gear (B) (6-speed model) on steel blocks (C), then use a press (D) and an attachment (E) to press the countershaft out of the ball bearing.
4. Remove the 35 mm shim and distance collar (5-speed model).





5. Support 4th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of the 5th gear.





6. Support 2nd gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of the 3rd gear.

Inspection





1. Inspect the gear surface and bearing surface for wear and damage, then measure the countershaft at points A, B. and C. If any part of the countershaft is less than the service limit, replace it with a new one.





2. Inspect the runout by supporting both ends of the countershaft. Rotate the countershaft two complete revolutions when measuring the runout. If the runout exceeds the service limit, replace the countershaft with a new one.

Reassembly

Special Tools Required
- Driver, 40 mm I.D.07746-0030100
- Attachment, 30 mm 07746-0030300

NOTE:
- Refer to the Exploded View as needed during this procedure.
- 6-speed model is shown, 5-speed model is similar.

1. Clean all parts in solvent, dry them, and apply lubricant to all contact surfaces.
2. Install the distance collar and needle bearing onto the countershaft.





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





4. Install the 1st/2nd synchro hub (A) by aligning the synchro cone fingers (B) with the grooves in 1st/2nd synchro hub (C).
5. Install the reverse gear.





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





8. Install the distance collar (A) and friction damper (B) by aligning the friction damper fingers (C) with the grooves in 1st/2nd synchro hub (D).
9. Install the needle bearing.





10. Install the 2nd gear (A) by aligning the synchro cone fingers (B) with the grooves in 2nd gear (C).





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





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





13. Install the 5th gear (A) using the special tool and a press (B).
14. Install the distance collar (5-speed model).





15. Install 6th gear (A) using a special tools and a press (B).





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





17. Measure the clearance between the old bearing (A) and the 35 mm shim (B) with a feeler gauge (C).
18. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in step 17 is within the standard, install the new ball bearing.





35 mm Shim





19. Support ball bearing (A) (5-speed model) or 6th gear (B) (6-speed model) on steel blocks (C), then use a press (D) and an attachment (E) to press the countershaft out of the ball bearing.
20. Replace the 35 mm shim selected in step 18, then recheck the clearance.





21. Install 6th gear (A) using a special tools and a press (B).





22. Install the new ball bearing (A) using a special tool and a press (B).





23. Tighten the new special bolt (A) (left-hand threads).