Countershaft Reassembly

Countershaft Reassembly

Countershaft:

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 manual transmission fluid (MTF) 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 the grooves in the 1st/2nd synchro hub (C).





5. Install the 1st/2nd synchro sleeve.
6. Install the synchro spring (A).





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





10. Support the countershaft (A) on the steel blocks, then install 3rd gear (B) using the 52 x 62 mm driver (C) and a press (D).





11. Install 4th gear (A) using the 52 x 62 mm driver (B) and a press (C).





12. Install 5th gear (A) using the 52 x 62 mm driver (B) and a press (C).





13. Install 6th gear (A) using the 40 mm I.D. driver (B) and a press (C).





14. Install the 35 mm shim (A) and the old ball bearing (B) using the 40 mm I.D. driver (C) and a press (D).





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 6th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft out of the old ball bearing.





18. If a new 35 mm shim was selected in step 16, install the shim, and recheck the clearance.
19. Install 6th gear (A) using the 40 mm I.D. driver (B) and a press (C).





20. Install the 35 mm shim (A) and new bearing (B) using the 40 mm I.D. driver (C) and a press (D).





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).

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