M/T Countershaft Reassembly

Exploded View


5-speed model:



6-speed model:

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

Attachment, 30 mm (  07746-0030300)



NOTE:

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 the 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 the 1st/2nd synchro hub grooves (D).

8.Install the distance collar (A) and friction damper (B) by aligning the friction damper fingers (C) with the 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 the 2nd gear grooves (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 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 (5-speed model).

15.Install 6th gear (A) using a special tools and a press (B). Do not exceed the maximum pressure.


16.Install the 35 mm shim and the old ball bearing (A) using a special tools and a press (B).

17.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.) 

18.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.

35 mm Shim
 Part Number Thickness 
A 23981-PPP-000 0.87 mm (0.034 in.) 
AA 23981-PPP-900 0.91 mm (0.036 in.) 
B 23982-PPP-000 0.95 mm (0.037 in.) 
AB 23982-PPP-900 0.99 mm (0.039 in.) 
C 23983-PPP-000 1.03 mm (0.041 in.) 
AC 23983-PPP-900 1.07 mm (0.042 in.) 
D 23984-PPP-000 1.11 mm (0.044 in.) 
AD 23984-PPP-900 1.15 mm (0.045 in.) 
E 23985-PPP-000 1.19 mm (0.047 in.) 
AE 23985-PPP-900 1.23 mm (0.048 in.) 
F 23986-PPP-000 1.27 mm (0.050 in.) 
AF 23986-PPP-900 1.31 mm (0.052 in.) 
G 23987-PPP-000 1.35 mm (0.053 in.) 
AG 23987-PPP-900 1.39 mm (0.055 in.) 
H 23988-PPP-000 1.43 mm (0.056 in.) 
AH 23988-PPP-900 1.47 mm (0.058 in.) 
J 23989-PPP-000 1.51 mm (0.060 in.) 
AJ 23989-PPP-900 1.55 mm (0.061 in.) 
K 23990-PPP-000 1.59 mm (0.063 in.) 
AK 23990-PPP-900 1.63 mm (0.064 in.) 
L 23991-PPP-000 1.67 mm (0.066 in.) 
AL 23991-PPP-900 1.71 mm (0.067 in.) 
M 23992-PPP-000 1.75 mm (0.069 in.) 
AM 23992-PPP-900 1.79 mm (0.070 in.) 
N 23993-PPP-000 1.83 mm (0.072 in.) 
AN 23993-PPP-900 1.87 mm (0.074 in.) 
P 23994-PPP-000 1.91 mm (0.075 in.) 
AP 23994-PPP-900 1.95 mm (0.077 in.) 
Q 23995-PPP-000 1.99 mm (0.078 in.) 

19.Support ball bearing (A) (5-speed model) or 6th gear (B) (6-speed model) on steel blocks (C), then use a press (D) and an attachment (E) to press the countershaft out of the ball bearing.

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

21.Install 6th gear (A) using a special tools and a press (B). Do not exceed the maximum pressure.

22.Install the new ball bearing (A) using a special tools and a press (B).

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