Countershaft Reassembly

Countershaft Reassembly

Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 25 mm I.D. 07746-0030200
^ Attachment, 30 mm I.D. 07746-0030300
^ Attachment, 35 mm I.D. 07746-0030400

NOTE: Refer to the Exploded View as needed during this procedure.

1. Clean all the parts in solvent, dry them, and apply lubricant all contact surfaces.
2. Install 1st gear, its bearing, and the friction damper on the shaft.





3. Install the 1st gear double cone synchro (A) and synchro spring (B) on the shaft.





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 shaft.





5. Install the reverse gear (A), synchro spring (B), and double cone synchro (C) on the shaft.





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





7. Install the needle bearing and 2nd gear (A), then align the holes (B) on the 2nd gear with the fingers (C) on the double cone synchro.





8. Install 3rd gear (A) using the special tools and a press (B).





9. Install 4th gear (A) using the special tools and a press (B).





10. Install 5th gear (A) using the special tools and a press (B).





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





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





13. Install the 22 mm spring washer (A) and 22 mm locknut (B).
14. Securely clamp the countershaft assembly in a bench vise with wood blocks.
15. Torque the new locknut to 108 Nm (11.0 kgf-cm, 79.6 ft. lbs.), then loosen it and torque it again to the same value. Stake the locknut tab into the groove.