Countershaft Reassembly

Special Tools Required 

Driver, 40 mm I.D. 07746-0030100

1. Install the 40.5 mm cotters (A), 2nd gear (B), the thrust needle bearing (C), the needle bearing (D), the idler gear (E), the thrust needle bearing (F), the 61 mm washer (G), 1st gear (H), 4th gear (I), the 50.8 mm collar (J), the 50.8 mm washer (K), the 42.2 mm cotters (L), the cotter retainer (M), and the snap ring (N) on the countershaft (O). Install the 40.5 mm cotters, the idler gear, 1st gear, and 4th gear in the direction shown.
   Fig 1: Exploded View Of Countershaft

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2. Install the thrust washer (P), the needle bearing (Q), and 5th gear (R).
3. Slide the reverse selector hub (A) over the countershaft (B), then press it into place using the driver, 40 mm and the press.
   NOTE: Some reverse selector hubs are not press-fitted, and can be installed without using the driver, 40 mm and a press.
   Fig 2: Installing Thrust Washer, Needle Bearing And 5th Gear

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4. Install the reverse selector, the reverse gear collar, the needle bearing, and the reverse gear over the reverse selector hub.
5. Install the ball bearing (A) over the countershaft, then press it into place using the driver, 40 mm and a press.
   Fig 3: Identifying Ball Bearing Over Countershaft

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6. Install a new conical spring washer (A) in the direction shown, and install a new locknut (B).
   Fig 4: Identifying Conical Spring Washer And Locknut

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7. Hold the countershaft securely using a wrench and a vise, and tighten the locknut to 167 N.m (17.0 kgf.m, 123 lbf.ft).
   NOTE:

   • Use a torque wrench to tighten the locknut. Do not use an impact wrench.
   • The locknut has left-hand threads.
     Fig 5: Holding Countershaft Securely Using Wrench And Vise

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8. Stake the locknut to a depth (A) of 0.7-1.3 mm (0.03-0.05 in.) using a 3.5 mm punch (B).
   Fig 6: Staking Locknut

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