M/T Countershaft Reassembly

Exploded View





 

Special Tools Required
Driver, 56 x 62 mm (  070AD-PYZA100)
 

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


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 countershaft reverse gear (A), needle bearing (B), and 1st gear (C) onto the countershaft (D).

 

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

 

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

 

5.Install the 1st/2nd synchro sleeve.

6.Install the synchro spring (A).

 

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

8.Install the distance collar and needle bearing.

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

 

10.Support the countershaft (A) on the steel blocks, then install 3rd gear (B) using the special tool and a press (C).

 

11.Install 4th gear (A) using the special tool and a press (B).

 

12.Install 5th gear (A) using the special tool and a press (B).

 

13.Install 6th gear (A) using the special tool and a press (B).

 

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

 

15.Measure the clearance between the old ball 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 (0.034 in.) 
AA 23981-PPP-900 0.91 mm (0.036 in.) 
23982-PPP-000 0.95 mm (0.037 in.) 
AB 23982-PPP-900 0.99 mm (0.039 in.) 
23983-PPP-000 1.03 mm (0.041 in.) 
AC 23983-PPP-900 1.07 mm (0.042 in.) 
23984-PPP-000 1.11 mm (0.044 in.) 
AD 23984-PPP-900 1.15 mm (0.045 in.) 
23985-PPP-000 1.19 mm (0.047 in.) 
AE 23985-PPP-900 1.23 mm (0.048 in.) 
23986-PPP-000 1.27 mm (0.050 in.) 
AF 23986-PPP-900 1.31 mm (0.052 in.) 
23987-PPP-000 1.35 mm (0.053 in.) 
AG 23987-PPP-900 1.39 mm (0.055 in.) 
23988-PPP-000 1.43 mm (0.056 in.) 
AH 23988-PPP-900 1.47 mm (0.058 in.) 
23989-PPP-000 1.51 mm (0.059 in.) 
AJ 23989-PPP-900 1.55 mm (0.061 in.) 
23990-PPP-000 1.59 mm (0.063 in.) 
AK 23990-PPP-900 1.63 mm (0.064 in.) 
23991-PPP-000 1.67 mm (0.066 in.) 
AL 23991-PPP-900 1.71 mm (0.067 in.) 
23992-PPP-000 1.75 mm (0.069 in.) 
AM 23992-PPP-900 1.79 mm (0.070 in.) 
23993-PPP-000 1.83 mm (0.072 in.) 
AN 23993-PPP-900 1.87 mm (0.074 in.) 
23994-PPP-000 1.91 mm (0.075 in.) 
AP 23994-PPP-900 1.95 mm (0.077 in.) 
23995-PPP-000 1.99 mm (0.078 in.) 

17.Support 6th gear (A) on steel blocks (B), then using a press (C) and an attachment (D), press the countershaft out of the old ball bearing.

 

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

19.Install 6th gear (A) using the special tool and a press (B).

 

20.Install the 35 mm shim (A) and new bearing (B) using the special tool and a press (C).

 


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

 

22.Tighten the new 20 mm special bolt (B) (left-hand threads).