NOTE: Lubricate all parts with ATF during assembly.
1. Assemble the parts below on the countershaft.
NOTE: Do not install the O-rings during inspection.
COTTERS
2ND GEAR SPACER
2ND GEAR
THRUST NEEDLE BEARING
3RD GEAR
NEEDLE BEARING
THRUST NEEDLE BEARING
3RD GEAR COLLAR
3RD CLUTCH ASSEMBLY
COUNTERSHAFT
2. Hold the 2nd gear against the 3rd gear. Measure the
clearance between the 3rd gear and thrust needle
bearing with a feeler gauge.
NOTE: Take measurements in at least three places
and take the average as the actual clearance.
2ND GEAR3RD GEAR
FEELER GAUGE
3RD GEAR COLLAR
TRUST
NEEDLE
BEARING
2ND GEAR3RD GEAR
Length
3RD GEAR
COLLAR
3RD GEAR COLLAR
(cont’d)
2ND GEAR SPACER
COTTER
FEELER GAUGE
2ND GEAR
3RD GEAR
COTTER
2ND GEAR SPACER
6. After replacing the cotters, make sure that the
clearance is held within tolerance.
7. Remove the countershaft bearing from the trans-
mission housing. See page 14-144.
8. Assemble the countershaft including bearing and
all parts shown to on page 14-124.
5. If the clearance is out of tolerance, select and install a
new cotters.
COTTER 31.5 mm
Countershaft
Inspection/Installation (cont’d)
3. If the clearance is out of tolerance;
-1. Select and install a new 3rd gear collar and
recheck the clearance.
-2. If the clearance is still out of tolerance, replace the
two thrust needle bearings and recheck the
clearance.
If the clearance still exceeds the service limit even
with new thrust needle bearings, check the 3rd
gear, 2nd gear and 3rd gear collar for wear, and
replace any worn parts.
After replacing parts, make sure that the clearance
is within tolerance.
NOTE:
4. Hold the 2nd gear against the 3rd gear. Measure the
clearance between the 2nd gear spacer and cotters
with a feeler gauge.
NOTE: Take measurements in at least three places,
and take the average as the actual clearance.
9. Torque the countershaft locknut to 30 N.m (3.0 kg-m,
22 Ib-ft).
COUNTERSHAFT BEARING
11. If the clearance is out of tolerance, select and install a
new cotter retainer.
THICKNESS
COTTER RETAINER
COTTER RETAINER
12. After replacing the cotter retainer, make sure that
the clearance is within tolerance.
LOCK NUT
30 N.m
(3.0 kg-m, 22 Ib-ft)
10. Measure the clearance between 4th gear and reverse
selector hub with a feeler gauge.
NOTE: Take measurements in at least three places,
and take the average as the actual clearance.
FEELER GAUGE
COTTER RETAINER
4TH GEAR
REVERSE SELECTOR HUB