Countershaft Disassembly/Inspection/Reassembly

Disassembly





1. Remove the needle bearing.





2. Remove the inner race (A) using a commercially available bearing separator and a press as shown.





3. Raise the 27 mm locknut tab from the groove in the countershaft.





4. Securely clamp the 4th and 5th gears in a bench vise with wood blocks (A).
5. Remove the 27 mm locknut (B) and spring washer (C).





6. Remove the ball bearing using a press as shown.
7. Remove the remaining parts from the countershaft.

Inspection
1. Inspect the gear surface and the bearing surface for wear and damage.





2. Measure the countershaft at points A, B, C, and D. If any part of the countershaft is less than the service limit, replace it with a new one.
Standard:
A (Rear cover end needle bearing contact area): 30.020 - 30.029 mm (1.1819 - 1.1822 inch)
B (Transmission housing end needle bearing contact area): 34.002 - 34.018 mm (1.3387 - 1.3393 inch)
C (2nd gear contact area): 43.984 - 44.000 mm (1.7317 - 1.7323 inch)
D (Clutch housing end ball bearing contact area): 28.002 - 28.015 mm (1.1024 - 1.1030 inch)
Service Limit:
A: 29.97 mm (1.180 inch)
B: 33.95 mm (1.337 inch)
C: 43.93 mm (1.730 inch)
D: 27.95 mm (1.100 inch)





3. Inspect for runout by supporting both ends of countershaft. Rotate the countershaft two complete revolutions when measuring the runout. If the runout is more than the service limit, replace the countershaft with a new one.
Standard: 0.02 mm (0.001 inch) maximum
Service Limit: 0.05 mm (0.002 inch)

Reassembly

Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ 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. Install the 44 x 50 x 28 mm needle bearing and 2nd gear.





2. Install the friction damper (A), double cone synchro (B), and synchro spring (C) as shown.





3. Install the 1-2 synchro hub (A) and sleeve (B) as shown.





4. Install the synchro spring (A) and double cone synchro (B) as shown.





5. Install the friction damper on the 1st gear, then install the 1st gear by aligning the grooves as shown.
6. Install the 51 x 57 x 23 mm needle bearing, distance collar, and 38 x 43 x 26 mm needle bearing.





7. Install the reverse gear.
8. Install the synchro ring and synchro spring.





9. Install the reverse synchro hub (A) and sleeve (B).





10. Install the ball bearing (A) using the special tools and a press as shown.





11. Securely clamp the 4th and 5th gears in a bench vise with wood blocks (A).
12. Install the spring washer (B) and 27 mm locknut (C).
13. Tighten the 27 mm locknut to the specified-value.
Torque: 162 -> 0 -> 162 Nm (16.5 -> 0 -> 16.5 kgf-m, 119 -> 0 -> 119 ft. lbs.)





14. Stake the locknut tab into the groove.





15. Install the needle bearing inner race (A) using the special tools and a Dress as shown.





16. Install the needle bearing.