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 and the needle bearing onto the countershaft.
  1. Install the 1st gear synchro ring (A), synchro spring (B) and the friction damper (C) on the 1st/2nd synchro hub (D).
  1. Align the fingers (E) on the friction damper with the grooves (F) on the 1st/2nd synchro hub, then install the 1st gear (G) onto the 1st/2nd synchro hub.
  1. Supporting by hand, turn the 1st/2nd synchro hub side upward, then install the 1st/2nd synchro hub with 1st gear on to the counter shaft.
  1. Support the countershaft (A) on the steel blocks, then press in the 1st/2nd synchro hub (B) with 1st gear (C) using the 40 mm inner driver handle (D) and 30 mm inner bearing driver attachment (E), and a press (F).
    NOTE: Do not exceed the maximum pressure.
  1. Install the reverse gear, synchro spring, and synchro ring on the shaft.
  1. Install the distance collar (A) and friction damper (B), by aligning the friction damper fingers (C) with the 1st/2nd synchro hub grooves (D).
  1. Install the needle bearing and 2nd gear.
  1. Support the countershaft (A) on the steel block, then press in the 3rd gear (B) using the 40 mm inner driver handle (C) and a press (D).
    NOTE: Do not exceed the maximum pressure.
  1. Press in the 4th gear (A) using the 40 mm inner driver handle (B) and a press (C).
    NOTE: Do not exceed the maximum pressure.
  1. Press in the 5th gear (A) using the 40 mm inner driver handle (B) and a press (C).
    NOTE: Do not exceed the maximum pressure.
  1. Press in the 6th gear (A) using the 40 mm inner driver handle (B) and 30 mm inner bearing driver attachment (C), and a press (D).
    NOTE: Do not exceed the maximum pressure.
  1. Install the 32 mm shim and temporary press in the used old ball bearing (A) using the 40 mm inner driver handle (B), 30 mm inner bearing driver attachment (C), and a press.
    NOTE:
    • The 35 mm shim are any type that is different its thickness. Note the type of installed shim.
    • Check the ball bearing install direction.
  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 (0.0016−0.0039 in.)

  1. If the measured clearance in Step 15 is without the standard, select another suitable 32 mm shim from the following table, then go to next step to replace the 32 mm shim and the ball bearing with new one. If the measured clearance in Step 15 is within the standard, go to next step to replace the only ball bearing with new one.

    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. Press in the 6th gear (A) using the 40 mm inner driver handle (B), 30 mm inner bearing driver attachment (C), and a press (D).
    NOTE: Do not exceed the maximum pressure.
  1. Install the 32 mm shim and the new ball bearing (A) using the 40 mm inner driver handle (B), 30 mm inner bearing driver attachment (C), and a press.
    NOTE:
    • If necessary, replace the 35 mm shim to proper one selected in Step 16 .
    • Check the ball bearing installing direction.
  1. Check the clearance between the bearing and the 32 mm shim with a feeler gauge.
  1. Securely clamp the countershaft assembly in a bench vise with wood blocks (A).
  1. Tighten the new special bolt (B) (left-hand threads).
    NOTE: Apply new MTF to the bolt threads and flange.