Countershaft
Disassembly
1. Drive out left bearing cone (2) with 4th gear (3) by using puller (4) and hydraulic press.
CAUTION:
^ Use puller and hydraulic 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 (5) to 2nd gear (4) and drive out 3rd & 4th gear spacer (2) and 3rd gear (3) together with 2nd gear by using hydraulic 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.
^ To avoid gear tooth from being damaged, support it at flat side of bearing puller.
3. Take out 2nd synchronizer outer ring, center cone and inner ring.
4. Using special tool, remove circlip (1).
NOTE: Correct tool tips to be flat to facilitate removal of circlip.
Special tool
(A): 09900-06107
5. Apply puller (3) to 1st gear (2) and drive out low speed synchronizer sleeve & hub assembly (1) with gear by using hydraulic press.
6. Disassemble synchronizer sleeve & hub assembly.
7. Take out needle bearing from shaft.
CAUTION: To avoid gear tooth from being damaged, support it at flat side of bearing puller.
8. Remove right bearing cone (2) by using puller (3), metal stick (1) and hydraulic press.
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 (2) and gear (1), each chamfered tooth of gear, ring and sleeve, then determine parts replacement.
Clearance "a" between synchronizer ring and gear
Standard: 1.0 - 1.4 mm (0.039 - 0.055 inch)
Service limit: 0.5 mm (0.019 inch)
3. Put the synchronizer outer ring (1), inner ring (3) and the cone (2) together and then measure the step difference between the outer ring and the inner ring. And also check each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.
Difference between synchronizer outer ring and inner ring
Standard "b": 1.0 - 1.4 mm (0.039 - 0.055 inch)
Service limit "b": 0.5 mm (0.019 inch)
4. To ensure lubrication of countershaft (1), air blow oil holes (2) and make sure that they are free from any obstruction.
5. Fit low speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as shown in figure.
NOTE:
^ No specific direction is assigned to each key but it is assigned as sleeve & hub assembly.
^ Size of low speed synchronizer keys and springs are the largest compared with those of high speed and 5th speed ones.
Synchronizer key installation position A = B
6. Install right bearing cone (1) by using special tool and hammer.
Special tool (A): 09923-78210
7. Install needle bearing, apply oil to it, then install 1st gear and 1st gear synchronizer ring.
8. Drive in low speed sleeve & hub assembly (1) by using special tools and hammer.
NOTE:
^ Support shaft with special tool as shown in figure so that refiner bearing cone (4) will be free from compression.
^ Make sure that synchronizer ring key slots (2) are aligned with keys while press-fitting sleeve 8 hub assembly.
^ Check free rotation of 1st gear (3) after press-fitting sleeve hub assembly.
Special tool
(A): 09923-78210
(B): 09913-85210
(C): 09940-54910
9. Install circlip (1) and confirm that circlip is installed in groove securely.
Install needle bearing (2) and apply oil to bearing.
With synchronizer outer ring (3), center cone (4) & inner ring (5) put together and installed to 2nd gear (6) as shown in figure.
10. Press-fit 3rd gear (2) and spacer (1) by using special tool and hydraulic 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): 09913-85210
11. Press-fit 4th gear (2) by using the same procedure.
12. Install left bearing cone (1) by using special tool and hammer.
NOTE: For protection of bearing cone (3), always support shaft with special tool as shown in figure.
Special tool
(A): 09923-78210
(E): 09913-80113