Countershaft Assembly

Disassembly





1. Drive out L bearing cone with 4th gear by using puller and press.

CAUTION:
^ Use puller and press that will bear at least 5 ton (11,000 lbs.) safely.
^ To avoid tooth damage, support 4th gear at flat side of puller.





2. Apply puller to 2nd gear and drive out 3rd & 4th gear spacer together with 2nd gear by using press. Needle bearing would come out with 2nd gear.

CAUTION: If compression exceeds 5 ton (11,000 lbs.), release compression once, reset puller support and then continue press work again.





3. Take out 2nd synchronizer ring.
4. Using special tool, remove circlip.

NOTE: Correct tool tips to be flat to facilitate removal of circlip.

Special Tool
(A): 09900-06107





5. Apply puller to 1st gear and drive out low speed synchronizer sleeve & hub assembly with gear by using press.
6. Disassemble synchronizer sleeve & hub assembly.
7. Take out needle bearing from shaft.





8. Remove R bearing cone by using puller, metal stick and press.

Inspection and Reassembly





1. Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
2. If synchronizer parts need to be repaired, check clearance "a" between ring and gear, each chamfered tooth of gear, ring and sleeve, then determine parts replacement.
Clearance "a":
Standard 1.0 - 1.4 mm (0.039 - 0.055 inch)
Service limit 0.5 mm (0.019 inch)





3. To ensure lubrication, air blow oil holes and make sure that they are free from any obstruction.





4. Fit high speed synchronizer sleeve to hub, insert 3 keys in it and then set springs as illustrated left.

NOTE:
^ No specific direction is assigned to low speed synchronizer hub or each key but it is assigned as assembly.
^ Size of low speed synchronizer keys and springs are the largest compared with those of high speed and 5th speed ones.





5. Install R bearing cone by using special tool and hammer.
Special Tool
(A): 09923-78210





6. Install needle bearing, apply oil to it, then install 1st gear and 1st gear synchronizer ring.

NOTE:
^ Key slot width of 1st synchronizer ring is smaller than that of 2nd synchronizer ring.
Distinguish the difference properly.
Width "b": 8.2 mm (0.32 inch)
"c": 9.6 mm (0.38 inch)
^ Needle bearings for 1st and 2nd gear are identical.





7. Drive in low speed sleeve & hub assembly by using special tool and hammer.

NOTE:
^ Support shaft with special tool as illustrated left so that retainer of bearing cone will be free from compression.
^ Make sure that synchronizer ring key slots are aligned with keys while press-fitting sleeve & hub assembly.
^ Check free rotation of 1st gear after press-fitting sleeve 8 hub assembly.

Special Tool
(A): 09923-78210
(B): 09925-18010
(C): 09940-53111





8. Install circlip, needle bearing, apply oil to bearing, then install 2nd gear synchronizer ring and 2nd gear.

CAUTION: Confirm that circlip is installed in groove securely.





9. Press-fit 3rd gear and spacer by using special tool and press.

NOTE: It is recommended to press-fit spacer and 3rd gear first, and then 4th gear later separately so that countershaft will not be compressed excessively.

Special Tool
(A): 09923-78210
(D): 09913-80112





10. Press-fit 4th gear by using the same procedure as the above.
11. Install L bearing cone by using special tool and hammer.

NOTE: For protection of bearing cone, always support shaft with special tool as illustrated.

Special Tool
(A): 09923-78210
(E): 09925-98221