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Î
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µµ
µµ
Standard: 28.03 28.08 mm (1.104 1.106 in.)
Standard: 27.92 27.97 mm (1.099 1.101 in.)
Service Limit: 27.87 mm (1.097 in.)
13-4213-42 Manual Transmission
Countershaft Assembly Clearance
Inspection (cont’d)
Countershaft Disassembly
A
C
D
B
5. Measure the length of the 2nd gear distance collar. If the length is not within the standard, replacethe 2nd gear distance collar.
If the length is within the standard, go to step 6.
6. Measure the thickness of 2nd gear. If the thickness is less than the service limit,replace 2nd gear.
If the thickness is within the service limit, replace the 1st/2nd synchro hub and the reverse gear as
aset. NOTE: Refer to the Exploded View in the Countershaft
Reassembly, as needed, when removing components
pressed on to the countershaft (see page 13-44).
1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
2. Remove the special bolt (left-hand threads).
3. Support the ball bearing (A) on steel blocks (B), then use a press (C) and an attachment (D) to press
the countershaft out of the ball bearing.
4. Removethe35mmshimandthedistancecollar.
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Page 818 of 2893

Î
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!)
µµ
µµ
Standard: 28.03 28.08 mm (1.104 1.106 in.)
Standard: 27.92 27.97 mm (1.099 1.101 in.)
Service Limit: 27.87 mm (1.097 in.)
13-4213-42 Manual Transmission
Countershaft Assembly Clearance
Inspection (cont’d)
Countershaft Disassembly
A
C
D
B
5. Measure the length of the 2nd gear distance collar. If the length is not within the standard, replacethe 2nd gear distance collar.
If the length is within the standard, go to step 6.
6. Measure the thickness of 2nd gear. If the thickness is less than the service limit,replace 2nd gear.
If the thickness is within the service limit, replace the 1st/2nd synchro hub and the reverse gear as
aset. NOTE: Refer to the Exploded View in the Countershaft
Reassembly, as needed, when removing components
pressed on to the countershaft (see page 13-44).
1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
2. Remove the special bolt (left-hand threads).
3. Support the ball bearing (A) on steel blocks (B), then use a press (C) and an attachment (D) to press
the countershaft out of the ball bearing.
4. Removethe35mmshimandthedistancecollar.
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DYNOMITE -2009-
Page 819 of 2893

(#'
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µµ
µµ
Standard:
A Ball Bearing Contact Area (transmission housing
side):30.020 30.033 mm (1.1819 1.1824 in.)
B 1st Gear Distance Collar Contact Area: 39.937 39.950 mm (1.5723 1.5728 in.)
C Needle Bearing Contact Area (clutch housing side):40.000 40.015 mm (1.5748 1.5754 in.)
Service Limit:
A: 29.97 mm (1.180 in.)
B: 39.88 mm (1.570 in.)
C: 39.95 mm (1.573 in.)
Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
13-4313-43
Countershaft Inspection
E
A
D
C
B
EA
D
C
B
C B
A
5. Support 4th gear (A) on steel blocks (B), then use apress (C) and an attachment (D) to press the
countershaft (E) out of 4th gear and 5th gear.
6. Support 2nd gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the
countershaft (E) out of 2nd gear and 3rd gear. 1. Inspect the gear and bearing contact areas for wear
and damage, then measure the countershaft at
points A, B, and C. If any part of the countershaft is
less than the service limit, replace it.
2. Inspect the runout by supporting both ends of the countershaft. Then rotate the countershaft two
complete turns while measuring with a dial gauge.
If the runout exceeds the service limit, replace the
countershaft.
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Page 820 of 2893
Î
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Exploded View
13-44Manual Transmission
Countershaft Reassembly
COUNTERSHAFT
3RD GEAR
NEEDLE BEARING 4TH GEAR 5TH GEAR
NEEDLE BEARING 35 mm SHIM
DISTANCE COLLAR
REVERSE GEAR
(1ST/2ND SYNCHRO
SLEEVE)
1ST GEAR
SYNCHRO SPRING
1ST GEAR
DISTANCE COLLAR
2ND GEAR
SYNCHRO CONE*
SYNCHRO RING* INNER RING*
SYNCHRO SPRING FRICTION DAMPER 2ND GEAR
DISTANCE COLLAR
SPECIAL BOLT
118 N·m (12 kgf·m, 87 lbf·ft)
1ST/2ND
SYNCHRO HUB
SYNCHRO CONE* SYNCHRO RING*
INNER RING* BALL BEARING
Check for wear
and operation. Check for wear
and operation.
*: The components of the triple cone synchro assembly. Check for wear
and damage.
Note the direction
of installation.
Replace.
NOTE: Left-hand threads.
Note the direction
of installation. Check for wear
and operation.
Note the direction
of installation.
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Page 821 of 2893

Î Î
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Special Tools Required
13-45
A
D B
C
D A
B
C A
B C
A
B
Inner driver handle, 40 mm 07746-0030100
Inner bearing driver attachment, 30 mm 07746-0030300
NOTE: Refer to the Exploded View, as needed, during
this procedure. 1. Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.
2. Install the 1st gear distance collar (A), the needle bearing (B), and 1st gear (C) onto the countershaft
(D).
3. Install the triple cone synchro assembly (A) by aligning the synchro cone fingers (B) with the
grooves (C) in 1st gear, then install the synchro
spring (D). 4. Install the 1st/2nd synchro hub (A) by aligning the
synchro ring fingers (B) with the grooves (C) in the
1st/2nd synchro hub.
5. Install the reverse gear (A) by aligning the slots of reverse gear and the 1st/2nd synchro hub (B). After
installing, check the operation of the 1st/2nd
synchro hub set.
NOTE: Make sure to align the slots in the 1st/2nd
synchro hub as shown.
(cont’d)
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Page 822 of 2893
Î
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13-46Manual Transmission
Countershaft Reassembly (cont’d)
C
D B
A
D
B
CA B
C A
D
C
07746-0030100 D
25,480 N
(2,600 kgf,
5,730 lbf) max.
A
B
6. Install the triple cone synchro assembly (A) with the
synchro spring (B) by aligning the synchro ring
fingers (C) with the grooves (D) in the 1st/2nd
synchro hub.
7. Install the distance collar (A) and the friction damper (B) by aligning the friction damper fingers
(C) with the grooves (D) in the 1st/2nd synchro hub. 8. Install the needle bearing (A).
9. Install 2nd gear (B) by aligning the synchro cone
fingers (C) with the grooves (D) in 2nd gear.
10. Support the countershaft (A) on steel blocks, then press on 3rd gear (B) using the 40 mm inner driver
handle (C) and a press (D).
NOTE: Do not exceed the maximum pressure.
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Page 823 of 2893
Î
Î
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13-47
B
07746-0030100
C
25,480 N
(2,600 kgf,
5,730 lbf) max.
A
B
07746-0030100C
25,480 N
(2,600 kgf,
5,730 lbf) max.
A D
07746-0030100
A
E
07746-0030300
B
C
C
F
11. Press on 4th gear (A) using the 40 mm inner driver
handle (B) and a press (C).
NOTE: Do not exceed the maximum pressure.
12. Press on 5th gear (A) using the 40 mm inner driver handle (B) and a press (C).
NOTE: Do not exceed the maximum pressure. 13. Install the distance collar (A) and the 35 mm shim
(B), and temporarily press on the used old ball
bearing (C) using the 40 mm inner driver handle (D),
the 30 mm inner bearing driver attachment (E), and
a press (F).
NOTE: Useanysizeof35mmshim,andnotesizeyou used. Measurements taken in the following steps
will determine the correct shim to use for final
assembly.
Make sure to install the ball bearing as shown.
(cont’d)
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Page 824 of 2893

Î
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Standard: 0.04 0.10 mm (0.0016 0.0039 in.)
35 mm ShimType Part Number Thickness
13-48Manual Transmission
Countershaft Reassembly (cont’d)
B
C A
14. Measure the clearance between the bearing (A) and
the 35 mm shim (B) with a feeler gauge (C). 15. If the measured clearance in step 14 is not within
the standard, select another suitable 35 mm shim
from the table, then go to next step to replace the
35 mm shim and the ball bearing with new one. If
the measured clearance in step 14 is within the
standard, go to next step to replace only the ball
bearing with new one.
A 23981- PPP-000 0.87 mm (0.034 in.)
AA 23981- PPP-900 0.91 mm (0.036 in.)
B 23982- PPP-000 0.95 mm (0.037 in.)
AB 23982- PPP-900 0.99 mm (0.039 in.)
C 23983- PPP-000 1.03 mm (0.041 in.)
AC 23983- PPP-900 1.07 mm (0.042 in.)
D 23984- PPP-000 1.11 mm (0.044 in.)
AD 23984- PPP-900 1.15 mm (0.045 in.)
E 23985- PPP-000 1.19 mm (0.047 in.)
AE 23985- PPP-900 1.23 mm (0.048 in.)
F 23986- PPP-000 1.27 mm (0.050 in.)
AF 23986- PPP-900 1.31 mm (0.052 in.)
G 23987- PPP-000 1.35 mm (0.053 in.)
AG 23987- PPP-900 1.39 mm (0.055 in.)
H 23988- PPP-000 1.43 mm (0.056 in.)
AH 23988- PPP-900 1.47 mm (0.058 in.)
J 23989- PPP-000 1.51 mm (0.060 in.)
AJ 23989- PPP-900 1.55 mm (0.061 in.)
K 23990- PPP-000 1.59 mm (0.063 in.)
AK 23990- PPP-900 1.63 mm (0.064 in.)
L 23991- PPP-000 1.67 mm (0.066 in.)
AL 23991- PPP-900 1.71 mm (0.067 in.)
M 23992- PPP-000 1.75 mm (0.069 in.)
AM 23992- PPP-900 1.79 mm (0.070 in.)
N 23993- PPP-000 1.83 mm (0.072 in.)
AN 23993- PPP-900 1.87 mm (0.074 in.)
P 23994- PPP-000 1.91 mm (0.075 in.)
AP 23994- PPP-900 1.95 mm (0.077 in.)
Q 23995- PPP-000 1.99 mm (0.078 in.)
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