M/T Countershaft Reassembly

Exploded View
Special Tools Required
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.
  1. Install the distance collar, the needle bearing, and 1st gear onto the countershaft.
  1. Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the grooves in 1st gear (C), then install the synchro spring (D).
  1. Install the 1st/2nd synchro hub (A) by aligning the synchro cone fingers (B) with the grooves in the 1st/2nd synchro hub (C).
  1. Install the reverse gear.
  1. Install the synchro spring (A).
  1. Install the double cone synchro assembly (B) by aligning the synchro cone fingers (C) with the grooves in the 1st/2nd synchro hub (D).
  1. Install the distance collar and needle bearing.
  1. Install 2nd gear (A) by aligning the synchro cone fingers (B) with the grooves in 2nd gear (C).
  1. 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.
  1. Install the 4th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.
  1. Install the 5th gear (A) using the special tool and a press (B). Do not exceed the maximum pressure.
  1. Install 6th gear (A) using the special tools and a press (B). Do not exceed the maximum pressure.
  1. Install the 32 mm shim and the old ball bearing (A) using the special tools and a press.
  1. Measure the clearance between the old bearing (A) and the 32 mm shim (B) with a feeler gauge (C).
    Standard:
    0.04−0.10 mm (0.016−0.0039 in.)

  1. If the clearance is more than the standard, select a new shim from the following table. If the clearance measured in Step 17 is within the standard, replace only the new ball bearing.

    32 mm Shim

    Part Number
    Thickness
    A
    23971-RPF-000
    1.56 mm (0.061 in.)
    B
    23972-RPF-000
    1.60 mm (0.063 in.)
    C
    23973-RPF-000
    1.64 mm (0.065 in.)
    D
    23974-RPF-000
    1.68 mm (0.066 in.)
    E
    23975-RPF-000
    1.72 mm (0.068 in.)
    F
    23976-RPF-000
    1.76 mm (0.069 in.)
    G
    23977-RPF-000
    1.80 mm (0.071 in.)
    H
    23978-RPF-000
    1.84 mm (0.072 in.)
    J
    23979-RPF-000
    1.88 mm (0.074 in.)
    K
    23980-RPF-000
    1.92 mm (0.076 in.)
    L
    23981-RPF-000
    1.96 mm (0.077 in.)
    M
    23982-RPF-000
    2.00 mm (0.079 in.)
    N
    23983-RPF-000
    2.04 mm (0.080 in.)
    P
    23984-RPF-000
    2.08 mm (0.082 in.)
    Q
    23985-RPF-000
    2.12 mm (0.083 in.)
    R
    23986-RPF-000
    2.16 mm (0.085 in.)
    S
    23987-RPF-000
    2.20 mm (0.087 in.)
    T
    23988-RPF-000
    2.24 mm (0.088 in.)
    U
    23989-RPF-000
    2.28 mm (0.090 in.)
    V
    23990-RPF-000
    2.32 mm (0.091 in.)

  1. Support 6th gear (A) on steel blocks (B) then use a press (C) and an attachment (D) to press the countershaft out of the ball bearing.
  1. If necessary, install the 32 mm shim selected in step 15, then recheck the clearance.
  1. Install 6th gear (A) using the special tools and a press (B). Do not exceed the maximum pressure.
  1. Install the new ball bearing (A) using the special tools and a press (B).
  1. Tighten the new special bolt (A) (left-hand threads).