M/T Countershaft Reassembly

Exploded View






 

Special Tools Required
Attachment, 42 x 47 mm (  07746-0010300)
 

Driver, 40 mm I.D. (  07746-0030100)
 
Attachment, 30 mm (  07746-0030300)
 
Driver (  07749-0010000)
 


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 and needle bearing onto the countershaft.

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

 

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

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

 

9.Install the needle bearing.

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

 

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

 

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

 

13.Install the 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 a 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 (0.002-0.004 in.) 

 

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

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

17.Support 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.Replace the 35 mm shim selected in step 16, then recheck the clearance.

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

 

20.Tighten the new special bolt (A) (left-hand threads).