Countershaft Disassembly, Reassembly, and Inspection (Except K20C1 (M/T))

Countershaft Disassembly, Reassembly, and Inspection

Special Tools Required

Image	Description/Tool Number
	Driver Handle, 40 mm I.D. 07746-0030100
	Bearing Driver Attachment, 30 mm I.D. 07746-0030300
	Driver, 58 x 62 mm 070AD-PYZA100

NOTE:

Where icon is shown, click for further information.

	Detailed information, notes, and precautions
	Replace
*1	Double cone synchro assembly
*2	Triple cone synchro assembly
*3	2.0 L Engine

1.	Special Bolt - Remove

Securely clamp the countershaft assembly in a bench vise with wood blocks.

Remove the special bolt (left-hand threads).

2.	Ball Bearing - Remove

Support 6th gear (A) on steel blocks, and press the countershaft (B) out of the ball bearing and 6th gear using an attachment (C) and a press (D).

3.	35 mm Shim - Remove

4.	6th Gear - Remove

5.	5th Gear - Remove

Support 4th gear (A) on steel blocks, and press the countershaft (B) out of 5th gear and 4th gear using an attachment (C) and a press (D).

6.	4th Gear - Remove

7.	3rd Gear - Remove

Support 2nd gear (A) on steel blocks, and press the countershaft (B) out of 3rd gear and 2nd gear using an attachment (C) and a press (D).

8.	2nd Gear - Remove

9.	Needle Bearing - Remove

10.	2nd Gear Distance Collar - Remove

11.	Friction Damper - Remove (2.0 L Engine)

12.	Inner Ring - Remove

13.	Synchro Cone - Remove

14.	Synchro Ring - Remove

15.	Synchro Spring - Remove

16.	1st/2nd Synchro Sleeve - Remove

17.	1st/2nd Synchro Hub - Remove

18.	Synchro Spring - Remove

19.	Synchro Ring - Remove

20.	Synchro Cone - Remove

21.	Inner Ring - Remove

22.	1st Gear - Remove

23.	Needle Bearing - Remove

24.	Counter Shaft Reverse Gear - Remove

1.	Countershaft - Inspect

Inspect the oil passage, gear, and bearing contact areas for wear and damage, then measure the countershaft at points A, B, C, and D. If any part of the countershaft is less than the service limit, replace it.

	Measurement	Standard	Service Limit
A	Ball Bearing Contact Area (Transmission Housing Side)	30.002?30.015 mm (1.18118?1.18169 in)	30.002 mm (1.18118 in)
B	2nd Gear Distance Collar Contact Area	42.937?42.950 mm (1.69043?1.69094 in)	42.937 mm (1.69043 in)
C	Countershaft Reverse Gear Contact Area	42.975?42.991 mm (1.69193?1.69256 in)	42.975 mm (1.69193 in)
D	Needle Bearing Contact Area (Clutch Housing Side)	40.000?40.015 mm (1.57480?1.57539 in)	40.000 mm (1.57480 in)

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 standard, replace the countershaft.

Standard:

0.02 mm (0.0008 in) max.

NOTE:

Where icon is shown, click for further information.

Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.

	Detailed information, notes, and precautions
	Torque: N·m (kgf·m, lbf·ft)
	Replace
*1	Double cone synchro assembly
*2	Triple cone synchro assembly
*3	2.0 L Engine

1.	Counter Shaft Reverse Gear - Install

2.	Needle Bearing - Install

3.	1st Gear - Install

4.	Inner Ring - Install

5.	Synchro Cone - Install

Install the synchro cone (A) by aligning the synchro cone fingers (B) with the holes (C) in 1st gear.

6.	Synchro Ring - Install

Install the synchro ring (A) by aligning the synchro ring fingers (B) with the grooves (C) in the inner ring (D).

7.	Synchro Spring - Install

8.	1st/2nd Synchro Hub - Install

Install the 1st/2nd synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 1st/2nd synchro hub.

9.	1st/2nd Synchro Sleeve - Install

Install the 1st/2nd synchro sleeve (A) by aligning the slots of the 1st/2nd synchro sleeve and the 1st/2nd synchro hub (B).

NOTE: Make sure to align the slots in the 1st/2nd synchro hub as shown.

Check the operation of the 1st/2nd synchro hub set.

10.	Synchro Spring - Install

11.	Synchro Ring - Install

Install the synchro ring (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 1st/2nd synchro hub.

12.	Synchro Cone - Install

13.	Inner Ring - Install

14.	Friction Damper - Install (2.0 L Engine)

15.	2nd Gear Distance Collar - Install

16.	Needle Bearing - Install

17.	2nd Gear - Install

Install 2nd gear (A) by aligning the synchro cone fingers (B) with the holes in 2nd gear (C).

18.	3rd Gear - Install

Support the countershaft (A) on steel blocks, then press on 3rd gear (B) using the 58 x 62 mm driver and a press (C).

NOTE: Do not exceed the maximum pressure.

19.	4th Gear - Install

Press on 4th gear (A) using the 58 x 62 mm driver and a press (B).

NOTE: Do not exceed the maximum pressure.

20.	5th Gear - Install

Press on 5th gear (A) using the 40 mm I.D. driver handle and a press (B).

NOTE: Do not exceed the maximum pressure.

21.	6th Gear - Install

Press on 6th gear (A) using the 40 mm I.D. driver handle and a press (B).

NOTE: Do not exceed the maximum pressure.

22.	35 mm Shim - Clearance Check

Install the 35 mm shim (A), and temporarily press on the used ball bearing (B) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and a press (C).

NOTE:

Use any size of 35 mm shim, and note size you used. Measurements taken in the following steps will determine the correct shim to use for final assembly.

Make sure the ball bearing is installed in the correct direction.

Measure the clearance between the ball bearing (A) and the 35 mm shim (B) with a feeler gauge (C).

Standard:

0.04?0.10 mm (0.002?0.003 in)

If the measured clearance 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 ones. If the measured clearance is within the standard, go to the next step to replace only the ball bearing with a new one.

35 mm Shim

Type	Thickness
A	0.86 mm (0.0339 in)
B	0.88 mm (0.0346 in)
C	0.90 mm (0.0354 in)
D	0.92 mm (0.0362 in)
E	0.94 mm (0.0370 in)
F	0.96 mm (0.0378 in)
G	0.98 mm (0.0386 in)
H	1.00 mm (0.0394 in)
J	1.02 mm (0.0402 in)
K	1.04 mm (0.0409 in)
L	1.06 mm (0.0417 in)
M	1.08 mm (0.0425 in)
N	1.10 mm (0.0433 in)
P	1.12 mm (0.0441 in)
Q	1.14 mm (0.0449 in)
R	1.16 mm (0.0457 in)
S	1.18 mm (0.0465 in)
T	1.20 mm (0.0472 in)
U	1.22 mm (0.0480 in)
V	1.24 mm (0.0488 in)
W	1.26 mm (0.0496 in)
X	1.28 mm (0.0504 in)
Y	1.30 mm (0.0512 in)
Z	1.32 mm (0.0520 in)
AA	1.34 mm (0.0528 in)
AB	1.36 mm (0.0535 in)
AC	1.38 mm (0.0543 in)
AD	1.40 mm (0.0551 in)
AE	1.42 mm (0.0559 in)
AF	1.44 mm (0.0567 in)
AG	1.46 mm (0.0575 in)
AH	1.48 mm (0.0583 in)
AJ	1.50 mm (0.0591 in)
AK	1.52 mm (0.0598 in)
AL	1.54 mm (0.0606 in)
AM	1.56 mm (0.0614 in)
AN	1.58 mm (0.0622 in)
AP	1.60 mm (0.0630 in)
AQ	1.62 mm (0.0638 in)
AR	1.64 mm (0.0646 in)
AS	1.66 mm (0.0654 in)
AT	1.68 mm (0.0661 in)
AU	1.70 mm (0.0669 in)
AV	1.72 mm (0.0677 in)
AW	1.74 mm (0.0685 in)
AX	1.76 mm (0.0693 in)
AY	1.78 mm (0.0701 in)
AZ	1.80 mm (0.0709 in)
AAA	1.82 mm (0.0717 in)
AAB	1.84 mm (0.0724 in)
AAC	1.86 mm (0.0732 in)
AAD	1.88 mm (0.0740 in)
AAE	1.90 mm (0.0748 in)
AAF	1.92 mm (0.0756 in)
AAG	1.94 mm (0.0764 in)
AAH	1.96 mm (0.0772 in)
AAJ	1.98 mm (0.0780 in)
AAK	2.00 mm (0.0787 in)

Remove 6th gear with the ball bearing and the 35 mm shim using a press.

Repeat step 21 (6th Gear - Install).

23.	35 mm Shim - Install

24.	Ball Bearing - Install

Install the ball bearing (A) using the 40 mm I.D. driver handle, the 30 mm I.D. bearing driver attachment, and a press (B).

NOTE:

If necessary, replace the 35 mm shim with the correct one selected in step 22-2 (35 mm Shim - Clearance Check).

Make sure the ball bearing is installed in the correct direction.

Recheck the clearance between the ball bearing and the 35 mm shim with a feeler gauge.

25.	Special Bolt - Install

Securely clamp the countershaft assembly in a bench vise with wood blocks (A).

Tighten a special bolt (B) (left-hand threads).