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.

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

1. 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).

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

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

1. Install the synchro spring (A).

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

1. Install the distance collar and needle bearing.

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

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

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

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

1. Install the distance collar (A) using the special tool and a press (B).

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

1. 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.)

1. If the clearance is more than the standard, select a new shim from the following table .
   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 (0.059 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.)

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

1. If a new 35 mm shim was selected in step 16, install the shim and recheck the clearance.

1. Install the distance collar (A) using the special tool and a press (B).

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

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

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