Countershaft Disassembly and Reassembly

Countershaft Disassembly and Reassembly

Manual Transmission Unit Disassembly

Disassembly

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 blocks (4) on vise (2) or the like to stop rotation of shaft, and then undo caulking and countershaft front bearing nut (3).

NOTE:
The countershaft will be damaged if its splines, gear teeth, or polished portion is griped with a vise.

Do not grip these portions with a vise.





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.

NOTE:
If the gear is supported on the concave side of the bearing puller, the teeth of the gear may be damaged.

Be sure to support the 2nd gear on the flat side of the bearing puller.





Reassembly

Countershaft and Reverse Idler Gear Inspection
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 hydraulic press.
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 hydraulic press.

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.

2nd gear thrust clearance
"a": 0.10 - 0.30 mm (0.004 - 0.012 in.)






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 hydraulic press.
Special Tool

(A): 09913-80113





10) Press-fit countershaft front bearing (1) using special tool and hydraulic press.
Special Tool

(A): 09913-84510





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 in.)






12) Tighten countershaft front bearing nut to specified torque while locking countershaft in the same manner as Step 2) of "Disassembly" under Countershaft Disassembly and Reassembly.

Tightening torque
Countershaft front bearing nut 210 Nm (21.0 kgf-m, 152.0 lbf-ft)

13) Caulk countershaft front bearing nut using caulking tool and hammer.