Special Tools Required
Driver, 40 mm I.D. ( 07746-0030100)
| 1. | Clean all the parts in solvent, dry them, and apply lubricant all contact surfaces. |
| 2. | Install the needle bearing (A), 1st gear (B), and friction damper (C) on the shaft. |
| 3. | Install the 1st gear synchro ring (D) and synchro spring (E) on the shaft.
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| 4. | Align the fingers (A) on the friction damper with the grooves (B) on the 1st/2nd synchro hub (C), then install the 1st/2nd synchro hub onto the shaft.
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| 5. | Install the reverse gear (A), synchro spring (B), and synchro ring (C) on the shaft.
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| 6. | Install the distance collar (A) and friction damper (B), then align the fingers (C) on the friction damper and grooves (D) in the 1st/2nd synchro hub.
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| 7. | Install the needle bearing (A) and 2nd gear (B).
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| 8. | Install the 3rd gear (A) using the special tools and a press (B).
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| 9. | Install the 4th gear (A) using the special tools and a press (B).
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| 10. | Install the 5th gear (A) using the special tools and a press (B).
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| 11. | Install the ball bearing (A) using the special tools and a press (B).
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| 12. | Install the ball bearing (A) using the special tools and a press (B).
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| 13. | Install the 22 mm spring washer (A) and 22 mm locknut (left-hand threads) (B).
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| 14. | Securely clamp the countershaft assembly in a bench vise with wood blocks. |
| 15. | Torque the new locknut to 108 N·m (11.0 kgf·m, 79.6 lbf·ft), then loosen it and torque it again to the same value. Stake the locknut tab into the groove. |