Countershaft Disassembly and Assembly
Countershaft Disassembly and AssemblyDisassembly
1. Remove countershaft rear bearing (1) using bearing puller, metal stick (2) and hydraulic press.
2. Hold hatched area (5) of countershaft assembly (1) with V blocks (4) on vise (2) or the like to stop rotation of shaft, undo caulking and countershaft front bearing nut (3).
CAUTION: Do not hold spline, gear teeth or abrasived surface of shaft with V blocks on vise or the like, otherwise shaft may be damaged.
3. Apply bearing puller to 2nd gear (1), and drive out countershaft front bearing (2), countershaft reverse gear (3), 1st gear (4), countershaft gear needle bearings, countershaft low needle bearing bush, low speed synchronizer assembly (5) and 2nd gear all at once from countershaft using metal stick (6) and hydraulic press.
CAUTION: To avoid gear teeth from being damaged, support 2nd gear at flat side of bearing puller.
Assembly
1. Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
2. To ensure lubrication, air blow oil holes (1) and make sure that they are free from any obstruction.
3. Drive in countershaft rear bearing (1) using special tool and hammer.
Special Tool (A): 09913-84510
4. Apply oil to countershaft gear needle bearing (6), and then install needle bearing, 2nd gear (5) and low speed synchronizer ring (7).
5. Assemble synchronizer sleeve (4) and hub (3) as follows.
a. Fit low speed synchronizer sleeve to hub in specified direction as shown in figure.
b. Insert 3 keys (2) to hub.
c. Set springs (1) at specified position as shown in figure.
Synchronizer key installation position: A = B
6. Drive in low speed synchronizer assembly (1) using special tool and hammer.
NOTE:
^ While press-fitting sleeve & hub, make sure that synchronizer ring key slots (2) are aligned with keys in sleeve & hub assembly.
^ Check free rotation of 2nd gear after press-fitting sleeve & hub assembly.
Special Tool (A): 09913-84510
7. Check 2nd gear (1) thrust clearance by using thickness gauge. If clearance is out of specification, repress-fit or replace defective part.
8. Apply oil to countershaft gear needle bearing, and then countershaft low needle bush, needle bearing and 1st gear (1) to countershaft.
9. Press-fit countershaft reverse gear (2) using special tool and hammer.
Special Tool (A): 09913-80113
10. Press-fit countershaft front bearing (1) using special tool and hammer.
11. Check low gear (1) thrust clearance by using thickness gauge. If clearance is out of specification, repress-fit or replace defective part.
Low gear thrust clearance "a": 0.10 - 0.30 mm (0.004 - 0.012 inch)
12. Tighten countershaft front bearing nut to specified torque while locking counter shaft in the same manner as step 2) of Disassembly under Countershaft Disassembly and Assembly.
CAUTION: Do not hold spline, gear teeth or abrasived surface of shaft with vise through "V" blocks or the like, otherwise shaft may be damaged.
Tightening torque
Countershaft front bearing nut: 210 Nm (21.0 kg-m, 152.0 ft. lbs.)
13. Caulk countershaft front bearing nut using caulking tool and hammer.