14. Countershaft Reassembly

Countershaft Reassembly

Countershaft 5-speed model:

Countershaft 6-speed model:

Special Tools Required
- Driver, 40 mm I.D. 07746-0030100
- Driver attachment, 30 mm I.D. 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, needle bearing, and 1st gear 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 ring grooves (B) with the fingers in the 1st/2nd synchro hub (C).





5. Install reverse gear.
6. Install the synchro spring (A).





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





9. Install the needle bearing.
10. Install 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 3rd gear (B) using the special tool and a press (C). Do not exceed the maximum pressure.





12. Install 4th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.





13. Install 5th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.





14. 5-speed model: Install the distance collar.
15. 6-speed model: Install 6th gear (A) using the special tools and a press (B). Do not exceed the maximum pressure.





16. Install the 35 mm shim and the old ball bearing (A) using the special tools 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, replace only the ball bearing.

35 mm Shim





19. Support the 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. If necessary, install the 35 mm shim selected in step 18, then recheck the clearance.
21. 6-speed model: Install 6th gear (A) using the special tools and a press (B). Do not exceed the maximum pressure.





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





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





24. Tighten the new special bolt (B) (left-hand threads).