5B
Countershaft Assembly Disassembly and Assembly
Disassembly
1) Remove countershaft rear bearing (1) using bearing puller, metal stick (2) and hydraulic press.
2) Remove countershaft front bearing nut in the same manner as Step 4) of “Disassembly” in Input Shaft Assembly Disassembly and Assembly:K9K Model .
3) Apply bearing puller to 2nd gear (1), and drive out countershaft front bearing (2), countershaft reverse gear (3), 1st gear (4), countershaft gear needle bearings, countershaft low needle bearing, low speed synchronizer assembly (5) and 2nd gear all at once from countershaft using metal stick (6) and hydraulic press.
CAUTION:
To avoid gear teeth from being damaged, support 2nd gear at flat side of bearing puller.
Assembly
1) Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
2) To ensure lubrication, air blow oil holes (1) and make sure that they are free from any obstruction.
3) Drive in countershaft rear bearing (1) using special tool and hammer.
Special Tool
(A) : 09913–84510
4) Apply oil to countershaft gear needle bearing, and then install needle bearing and 2nd gear.
5) Assemble synchronizer sleeve (4) and hub (3) as follows.
a) Fit low speed synchronizer sleeve to hub in specified direction as shown in the figure.
b) Insert 3 keys (2) to hub.
c) Set springs (1) at specified position as shown in the figure.
Synchronizer key installation position
A = B
[A]: 1st gear side D: Chamfered side
C: Key way 5. 2nd gear
6) Drive in low speed synchronizer assembly (1) using special tool and hammer.
NOTE:
While press-fitting sleeve & hub, make sure that synchronizer ring key slots (2) are aligned with keys in sleeve & hub assembly.
Check free rotation of 2nd gear after press-fitting sleeve & hub assembly.
Special Tool
(A) : 09913–84510
7) Install countershaft gear needle bearing, and then countershaft low needle bush, needle bearing and 1st gear (1) to countershaft.
8) Press-fit countershaft reverse gear (2) using special tool and hammer.
Special Tool
(A) : 09913–80113
9) Press-fit countershaft front bearing (1) using special tool and hammer.
Special Tool
(A) : 09913–84510
10) Hold countershaft with vise through woodblock, tighten countershaft front bearing nut to specified torque.
Tightening torque
Countershaft front bearing nut : 210 N·m ( 21.0 kg-m, 152.0 lb-ft)
CAUTION:
Do not hold spline, gear teeth or abrasived surface of shaft with vise, otherwise shaft may be damaged.
11) Caulk countershaft front bearing nut using caulking tool and hammer.