COUNTER GEAR DISASSEMBLY

PROCEDURE


  1. INSPECT COUNTERSHAFT REVERSE GEAR THRUST CLEARANCE


    1. B003NSE

      Using a dial indicator, measure the countershaft reverse gear thrust clearance.

      Standard Clearance
      0.150 to 0.300 mm (0.0060 to 0.0118 in.)

      If the clearance is outside the specification, replace the countershaft reverse gear, reverse gear bearing inner race or No. 4 transmission clutch hub.

      Tech Tips

      Replace the part or parts determined to be the most likely cause of the problem.

  2. INSPECT COUNTERSHAFT REVERSE GEAR RADIAL CLEARANCE


    1. B003QMO

      Using a dial indicator, measure the countershaft reverse gear radial clearance.

      Standard Clearance
      0.015 to 0.065 mm (0.0006 to 0.0025 in.)

      If the clearance is outside the specification, replace the countershaft reverse gear, reverse gear bearing inner race or needle roller bearing.

      Tech Tips

      Replace the part or parts determined to be the most likely cause of the problem.

  3. INSPECT COUNTERSHAFT 1ST SPEED GEAR THRUST CLEARANCE


    1. B003POG

      Using a dial indicator, measure the countershaft 1st speed gear thrust clearance.

      Standard Clearance
      0.150 to 0.480 mm (0.0060 to 0.0188 in.)

      If the clearance is outside the specification, replace the countershaft 1st speed gear, clutch hub or counter gear.

      Tech Tips

      Replace the part or parts determined to be the most likely cause of the problem.

  4. INSPECT COUNTERSHAFT 1ST SPEED GEAR RADIAL CLEARANCE


    1. B003MDK

      Using a dial indicator, measure the countershaft 1st speed gear radial clearance.

      Standard Clearance
      0.015 to 0.067 mm (0.0006 to 0.0026 in.)

      If the clearance is outside the specification, replace the countershaft 1st speed gear, 1st gear needle roller bearing or shaft.

      Tech Tips

      Replace the part or parts determined to be the most likely cause of the problem.

  5. INSPECT COUNTERSHAFT 2ND SPEED GEAR THRUST CLEARANCE


    1. B003RZX

      Using a dial indicator, measure the countershaft 2nd speed gear thrust clearance.

      Standard Clearance
      0.150 to 0.480 mm (0.0060 to 0.0188 in.)

      If the clearance is outside the specification, replace the countershaft 2nd speed gear, clutch hub or counter gear.

      Tech Tips

      Replace the part or parts determined to be the most likely cause of the problem.

  6. INSPECT COUNTERSHAFT 2ND SPEED GEAR RADIAL CLEARANCE


    1. B003OS1

      Using a dial indicator, measure the countershaft 2nd speed gear radial clearance.

      Standard Clearance
      0.015 to 0.067 mm (0.0006 to 0.0026 in.)

      If the clearance is outside the specification, replace the countershaft 2nd speed gear, 2nd gear needle roller bearing or shaft.

      Tech Tips

      Replace the part or parts determined to be the most likely cause of the problem.

  7. REMOVE REAR COUNTER GEAR BEARING SNAP RING


    1. B003OHF

      Using a snap ring expander, remove the rear counter gear bearing snap ring from the counter gear.

  8. REMOVE REAR COUNTER GEAR BEARING OR ROLLER


    1. B003N0UN01

      Using SST, remove the rear counter gear bearing or roller (inner races) from the counter gear.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04010, 09954-04010, 09955-04071, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00320 )

  9. REMOVE COUNTERSHAFT REVERSE GEAR


    1. B003MB8C02
      *1 Front Counter Gear Bearing or Roller
      *2 Center Counter shaft Bearing
      *3 Countershaft Reverse Gear

      Using SST and a press, remove the front counter gear bearing or roller, center counter shaft bearing, and countershaft reverse gear from the counter gear.

      SST
      09555-55010
      09950-70010   ( 09951-07100 )
      09950-60010   ( 09951-00320 )

      Note

      Support the counter gear by hand so that it does not fall.

  10. REMOVE REVERSE GEAR BEARING


    1. Remove the reverse gear bearing and reverse gear bearing inner race from the countershaft reverse gear.

  11. REMOVE REVERSE SHIFT RESTRICT BALL


    1. Remove the reverse shift restrict ball from the counter gear.

  12. REMOVE REVERSE SYNCHRONIZER RING


    1. Remove the reverse synchronizer ring from the counter gear.

  13. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY SPRING


    1. Remove the No. 3 synchromesh shifting key spring from the counter gear.

  14. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY


    1. Remove the 2 No. 3 synchromesh shifting keys from the counter gear.

  15. REMOVE NO. 4 TRANSMISSION HUB SLEEVE


    1. Remove the No. 4 transmission hub sleeve from the No. 4 transmission clutch hub.

  16. REMOVE NO. 4 TRANSMISSION CLUTCH HUB


    1. B003KGCN01

      Using SST and a press, remove the No. 4 transmission clutch hub and countershaft 1st speed gear from the counter gear.

      SST
      09555-55010
      09950-70010   ( 09951-07100 )
      09950-60010   ( 09951-00320 )

      Note


      • Do not insert SST deep inside the gear, as this may damage the synchronizer ring.

      • B003OC1N01

        Use SST in the position shown in the illustration.

  17. REMOVE 1ST GEAR NEEDLE ROLLER BEARING


    1. Remove the 1st gear needle roller bearing from the counter gear.

  18. REMOVE NO. 1 SYNCHRONIZER RING SET


    1. Remove the No. 1 synchronizer ring set from the counter gear.

  19. REMOVE NO. 1 TRANSMISSION HUB SLEEVE


    1. Remove the No. 1 transmission hub sleeve from the No. 1 transmission clutch hub.

  20. REMOVE NO. 1 SYNCHROMESH SHIFTING KEY


    1. Remove the 3 No. 1 synchromesh shifting keys from the No. 1 transmission clutch hub.

  21. REMOVE NO. 1 CLUTCH HUB SHAFT SNAP RING


    1. B003KLB

      Using a snap ring expander, remove the No. 1 clutch hub shaft snap ring from the counter gear.

  22. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    1. B003LLSN01

      Using SST and a press, remove the countershaft 2nd speed gear, No. 2 synchronizer ring set and No. 1 transmission clutch hub from the counter gear.

      SST
      09555-55010
      09950-70010   ( 09951-07100 )
      09950-60010   ( 09951-00320 )

  23. REMOVE 2ND GEAR NEEDLE ROLLER BEARING


    1. Remove the 2nd gear needle roller bearing from the counter gear.