Countershaft Disassembly and Reassembly
Countershaft Disassembly and ReassemblyDisassembly
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 lb) safely.
^ To avoid tooth damage, support 4th gear (3) 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 lb), release compression once, reset bearing puller 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 snap ring pliers (3), remove circlip (1).
NOTE: Correct tool tips to be flat to facilitate removal of circlip.
5. Apply puller (3) to 1st gear (2) and drive out low speed synchronizer sleeve & hub assembly (1) with 1st gear by using hydraulic press.
CAUTION: To avoid gear tooth from damage, support it at flat side of bearing puller.
6. Disassemble synchronizer sleeve & hub assembly.
7. Take out 1st gear needle bearing from shaft.
8. In order to remove right bearing (1) from countershaft, grind with a grinder (2) one part "a" of right bearing (1) as illustrated till it becomes thin.
CAUTION: Be careful not to grind too far not to damage the shaft (3).
9. Break with a chisel (1) the thin ground right bearing (2) and it can be removed.
Reassembly
1. Clean all components thoroughly, inspect them for any abnormality and replace with new one as necessary.
2. Check clearance "a" between synchronizer ring (2) and gear (1), key slot width "b" in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.
Clearance "a" between synchronizer ring and gear
Standard: 1.0 - 1.4 mm (0.040 - 0.055 in.)
Service limit: 0.5 mm (0.020 in.)
Key slot width "b"
Standard: 10.0 - 10.2 mm (0.394 - 0.401 in.)
Limit: 10.45 mm (0.411 in.)
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 (2nd)
Standard "b": 0.95 - 1.25 mm (0.036 - 0.048 in.)
Service limit "b": 0.5 mm (0.019 in.)
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 larger than those of high speed one.
Synchronizer key installation position A = B
6. Install right bearing cone (1) to counter shaft (2) by using special tools and hydraulic press.
Special Tool
(A):09913-76010
(B):09924-07720
7. Install needle bearing (4), apply oil to it, then install 1st gear and 1st gear synchronizer ring (2).
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 retainer of bearing cone (4) will be free from compression.
^ Make sure that synchronizer ring key slots are aligned with keys (5) while press-fitting sleeve & 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
(D):09924-07710
9. Install circlip (1) and confirm that circlip is installed in groove securely.
Install needle bearing (2) and apply oil to needle bearing.
With synchronizer outer ring (3), center cone (4) and 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 tools 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
(B):09913-85210
11. Press-fit 4th gear (2) by using the same procedure at step 10).
12. Install left bearing cone (1) by using special tool and hydraulic press.
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
