COUNTER GEAR REASSEMBLY

PROCEDURE


  1. INSTALL COUNTER SHAFT 3RD GEAR


    1. A004KK5

      Apply manual transmission gear oil to the mounting point of the counter shaft, needle roller bearing and inside surface and taper cone of the counter shaft 3rd gear.

    2. Install the needle roller bearing and counter shaft 3rd gear.

  2. INSTALL NO. 2 TRANSMISSION HUB SLEEVE


    1. A004J16E02
      Text in Illustration
      *1 No. 2 Transmission Clutch Hub
      *2 No. 2 Transmission Hub Sleeve
      *3 Ball
      *4 No. 1 Synchromesh Shifting Key
      *5 No. 1 Synchromesh Shifting Key Spring
      A004I9S Front Side

      Apply manual transmission gear oil to the moving parts of the No. 2 transmission clutch hub.

    2. As shown in the illustration, install the No. 2 transmission hub sleeve to the No. 2 transmission clutch hub. Install the 3 No. 1 synchromesh shifting keys and 3 No. 1 synchromesh shifting key springs all together, and then install the balls.

      Tech Tips


      • Install the shifting key ball while holding down the synchromesh shifting key spring. Install the ball while holding down the No. 1 synchromesh shifting key spring.


      • After the installation, let the No. 1 synchromesh shifting key spring settle down.

  3. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. A004JSJE01

      Install the No. 3 synchronizer ring set to the counter shaft 3rd gear.

      Tech Tips


      • Align the middle ring claw with the groove in the counter shaft 3rd gear.

      • Align the inner ring claw with the groove in the outer ring.

    2. Using SST and a press, install the No. 2 transmission clutch hub.

      SST
      09316-60011   ( 09316-00011 )

      Note

      Make sure that the No. 3 synchronizer ring set is positioned properly.

      Tech Tips


      • Align the No. 2 transmission clutch hub and the No. 3 synchronizer ring set so that they can fit together.

      • Make sure to press fit the No. 2 transmission clutch hub until it touches the counter shaft.


      • After the press fit, make sure that the No. 3 synchronizer ring set moves toward the thrust direction.

  4. INSTALL COUNTER SHAFT 4TH GEAR


    1. A004J1V

      Install the No. 1 synchronizer ring to the No. 2 transmission clutch hub.

      Tech Tips

      Align the No. 2 transmission clutch hub and the No. 1 synchronizer ring so that they can fit together.

    2. Apply manual transmission gear oil to the 4th gear bearing inner race and inside surface and taper cone of the counter shaft 4th gear.

    3. Install the counter shaft 4th gear and 4th gear bearing inner race.

      Tech Tips

      To install it, rotate the 4th gear bearing inner race along the gear in a clockwise direction.

  5. INSTALL 4TH INNER RACE THRUST WASHER


    1. A004HWLE02
      Text in Illustration
      *1 4th Inner Race Thrust Washer
      A004I9S Front Side

      Select a 4th inner race thrust washer that is suitable to retain the specific thrust clearance between the 4th gear bearing inner race and 4th inner race thrust washer.

      Standard clearance
      0 to 0.1 mm (0 to 0.00394 in.)

      Tech Tips

      Select the thickest 4th inner race thrust washer possible for installation.

      4th Inner Race Thrust Washer Thickness
      Part No. Thickness mm (in.) Mark
      SU003-03500 3.75 (0.14763) A
      SU003-03501 3.80 (0.14960) B
      SU003-03502 3.85 (0.15157) C
      SU003-03503 3.90 (0.15354) D
      SU003-03504 3.95 (0.15551) E
      SU003-03505 4.00 (0.15748) F
      SU003-03506 4.05 (0.15944) G
      SU003-03507 4.10 (0.16141) H

    2. Using a snap ring expander, as shown in the illustration, install a new 4th inner race thrust washer, new 4th washer retaining ring and new shaft snap ring to the counter shaft.

  6. INSTALL COUNTER DRIVE GEAR


    1. A004IGAE01

      Using SST and a press, install the counter drive gear.

      SST
      09309-36010

  7. INSTALL SHAFT SNAP RING (for Counter Drive Gear)


    1. A004JM5

      Select a shaft snap ring that is suitable to retain the specific thrust clearance between the counter drive gear and shaft snap ring.

      Standard clearance
      0 to 0.1 mm (0 to 0.00394 in.)

      Tech Tips

      Select the thickest shaft snap ring possible for installation.

      Shaft Snap Ring Thickness
      Part No. Thickness: mm (in.) Mark
      SU003-03581 1.80 (0.07086) A
      SU003-03582 1.85 (0.07283) B
      SU003-03583 1.90 (0.07480) C
      SU003-03584 1.95 (0.07677) D
      SU003-03585 2.00 (0.07874) E
      SU003-03586 2.05 (0.08070) F

    2. Using a snap ring expander, install a new shaft snap ring to the counter shaft.

  8. INSTALL FRONT COUNTER GEAR BEARING


    1. A004IYIE03
      Text in Illustration
      *1 Front Counter Gear Bearing
      A004I9S Front Side

      Using SST and a press, as shown in the illustration, install a new front counter gear bearing while holding it with your hand.

      SST
      09330-50010

      Note

      Attach SST to the inner race of the front counter gear bearing, and then install the front counter gear bearing.

  9. INSTALL SHAFT SNAP RING (for Front Counter Gear Bearing)


    1. A004IR7

      Select a shaft snap ring that is suitable to retain the specific thrust clearance between the counter gear front bearing and shaft snap ring.

      Standard clearance
      0 to 0.1 mm (0 to 0.00394 in.)

      Tech Tips

      Select the thickest shaft snap ring possible for installation.

      Shaft Snap Ring Thickness
      Part No. Thickness: mm (in.) Mark
      SU003-03560 2.05 (0.08070) 1
      SU003-03558 2.10 (0.08267) 2
      SU003-03561 2.15 (0.08464) 3
      SU003-03559 2.20 (0.08661) 4
      SU003-03562 2.25 (0.08858) 5
      SU003-03563 2.30 (0.09055) 6

    2. Using a snap ring expander, install a new shaft snap ring to the counter shaft.