M/T Countershaft Reassembly

Exploded View


 

Special Tools Required
Driver, 40 mm I.D. (  07746-0030100)
 

Driver, 30 mm (  07746-0030300)
 


NOTE: Refer to the Exploded View as needed during this procedure.

1.Clean all parts in solvent, dry them, and apply lubricant to all contact surfaces.

2.Install the distance collar, the needle bearing, and 1st gear onto the countershaft.

3.Install the triple cone synchro assembly (A) by aligning the synchro cone fingers (B) with the grooves in 1st gear (C), then install the synchro spring (D).

 

4.Install the 1st/2nd synchro hub (A) by aligning the synchro cone fingers (B) with the grooves in the 1st/2nd synchro hub (C).

 

5.Install the reverse gear.

6.Install the synchro spring (A).

 

7.Install the triple cone synchro assembly (B) by aligning the synchro cone fingers (C) with the grooves in the 1st/2nd synchro hub (D).

8.Install the distance collar (A) and friction damper (B) by aligning the friction damper fingers (C) with the grooves in the 1st/2nd synchro hub (D).

 

9.Install the needle bearing.

10.Install 2nd gear (A) by aligning the synchro cone fingers (B) with the grooves in 2nd gear (C).

 

11.Support the countershaft (A) on the steel blocks, then install 3rd gear (B) using the special tool and a press (C). Do not exceed the maximum pressure.

 

12.Install 4th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.

 

13.Install 5th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.

 

14.Install the distance collar (A), 35 mm shim, and old ball bearing (B) using the special tools and a press (C).

 

15.Measure the clearance between the old bearing (A) and the 35 mm shim (B) with a feeler gauge (C).

Standard: 0.04-0.10 mm (0.0016-0.0039 in.) 

 

16.If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in 15 is within the standard, replace only the ball bearing.

35 mm Shim
 Part Number Thickness 
23981-PPP-000 0.87 mm (0.0343 in.) 
AA 23981-PPP-900 0.91 mm (0.0358 in.) 
23982-PPP-000 0.95 mm (0.0374 in.) 
AB 23982-PPP-900 0.99 mm (0.0390 in.) 
23983-PPP-000 1.03 mm (0.0406 in.) 
AC 23983-PPP-900 1.07 mm (0.0421 in.) 
23984-PPP-000 1.11 mm (0.0437 in.) 
AD 23984-PPP-900 1.15 mm (0.0453 in.) 
23985-PPP-000 1.19 mm (0.0469 in.) 
AE 23985-PPP-900 1.23 mm (0.0484 in.) 
23986-PPP-000 1.27 mm (0.0500 in.) 
AF 23986-PPP-900 1.31 mm (0.0516 in.) 
23987-PPP-000 1.35 mm (0.0531 in.) 
AG 23987-PPP-900 1.39 mm (0.0547 in.) 
23988-PPP-000 1.43 mm (0.0563 in.) 
AH 23988-PPP-900 1.47 mm (0.0579 in.) 
23989-PPP-000 1.51 mm (0.0594 in.) 
AJ 23989-PPP-900 1.55 mm (0.0610 in.) 
23990-PPP-000 1.59 mm (0.0626 in.) 
AK 23990-PPP-900 1.63 mm (0.0642 in.) 
23991-PPP-000 1.67 mm (0.0657 in.) 
AL 23991-PPP-900 1.71 mm (0.0673 in.) 
23992-PPP-000 1.75 mm (0.0689 in.) 
AM 23992-PPP-900 1.79 mm (0.0705 in.) 
23993-PPP-000 1.83 mm (0.0720 in.) 
AN 23993-PPP-900 1.87 mm (0.0736 in.) 
23994-PPP-000 1.91 mm (0.0752 in.) 
AP 23994-PPP-900 1.95 mm (0.0768 in.) 
23995-PPP-000 1.99 mm (0.0783 in.) 

17.Support the ball bearing (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the countershaft (E) out of the ball bearing.

 

18.If necessary, install the 35 mm shim selected in 16, then recheck the clearance.

19.Install the distance collar (A), the 35 mm shim, and the new ball bearing (B) using the special tools and a press (C).

 

20.Securely clamp the countershaft assembly in a bench vise with wood blocks (A).

 

21.Tighten the new special bolt (B) (left-hand threads).