Component Disassembly & Reassembly: Countershaft: Reassembly
NOTE:
Countershaft 3rd gear and 2nd gear clearance must be checked before reassembly.
- Countershaft 3rd gear clearance must be checked. Proper length 3rd gear distance collar must be installed to obtain correct countershaft 3rd gear clearance.
- Assemble 3rd gear distance collar, needle bearing, thrust needle bearing, countershaft 3rd gear, thrust needle bearing and countershaft 2nd gear on 3rd clutch. See Figure .
- Hold 3rd clutch stationary. Press countershaft 2nd gear against 3rd clutch with 12 lbs. (10 kg) of force. Ensure countershaft 3rd gear rotates manually without binding, and no up and down movement exists on countershaft 3rd gear. See Fig 1 .
- If binding exists, install longer 3rd gear distance collar. If up-and-down movement exists, install shorter 3rd gear distance collar. See 3RD GEAR DISTANCE COLLAR SPECIFICATIONS table. If proper operation of countershaft 3rd gear cannot be obtained by changing length of distance collar, check components for wear.
- Once correct 3rd gear distance collar is obtained, lubricate all components with ATF. Wrap splines of countershaft with tape. Install NEW "O" rings on countershaft.
- Assemble 3rd gear distance collar, needle bearing, thrust needle bearing, countershaft 3rd gear, thrust needle bearing and countershaft 2nd gear on 3rd clutch. See Figure .
- Install 3rd clutch and components on countershaft. Ensure splines on countershaft align with splines of countershaft 2nd gear and 3rd clutch.
- Place assembly in hydraulic press while supporting 3rd clutch. Press countershaft into 3rd clutch until final drive gear on countershaft contacts 3rd clutch.
- To check countershaft 2nd gear clearance, install all components, except "O" rings, on countershaft. Assemble 3rd gear distance collar, needle bearing, thrust needle bearing, countershaft 3rd gear, thrust needle bearing and countershaft 2nd gear on 3rd clutch. See Figure .
- Install transaxle housing bearing, collar, needle bearing, countershaft 1st gear, one-way clutch and parking gear on countershaft. See Figure . Remove joint bolts.
- Install used lock nut on countershaft. Tighten lock nut to 22 ft. lbs. (30 N.m). To check countershaft 2nd gear clearance, hold selector hub against countershaft 4th gear.
- Install feeler gauge between countershaft reverse gear and selector hub against countershaft 4th gear. See Fig 2 .
- Using feeler gauge, measure countershaft 2nd gear clearance between distance collar and countershaft 2nd gear. See Fig 2 . Measure countershaft 2nd gear clearance in 3 areas, and take average of measurements. Countershaft 2nd gear clearance should be 0.0-.0016" (0-.040 mm).
- If clearance is not within specification, install different length distance collar between countershaft 2nd gear and countershaft 4th gear. See 2ND GEAR DISTANCE COLLAR SPECIFICATIONS table. If shortest distance collar is installed and clearance still exceeds specification, check components for wear.
NOTE:
Ensure thrust needle bearings and needle bearings are installed with unrolled edge of bearing retainer facing washer.
3RD GEAR DISTANCE COLLAR SPECIFICATIONS
| Collar No. | Part Number | Length In. (mm) |
|---|---|---|
| 1 | 90498-PR9-000 | 1.0218-1.0224 (25.955-25.970) |
| 2 | 90499-PR9-000 | 1.0224-1.0230 (25.970-25.985) |
| 3 | 90500-PR9-000 | 1.0230-1.0236 (25.985-26.000) |
| 4 | 90501-PR9-000 | 1.0236-1.0242 (26.000-26.015) |
| 5 | 90511-PR9-000 | 1.0242-1.0248 (26.015-26.030) |
| 6 | 90512-PR9-000 | 1.0248-1.0254 (26.030-26.045) |
2ND GEAR DISTANCE COLLAR SPECIFICATIONS
| Collar No. | Part Number | Length In. (mm) |
|---|---|---|
| 1 | 90503-PRO-030 | .9087-.9094 (23.080-23.100) |
| 2 | 90504-PRO-030 | .9094-.9102 (23.100-23.120) |
| 3 | 90505-PRO-030 | .9102-.9110 (23.120-23.140) |
| 4 | 90506-PRO-030 | .9110-.9118 (23.140-23.160) |
| 5 | 90507-PRO-030 | .9118-.9126 (23.160-23.180) |
| 6 | 90508-PRO-030 | .9126-.9134 (23.180-23.200) |
| 7 | 90509-PRO-030 | .9134-.9142 (23.200-23.220) |
| 8 | 90531-PRO-010 | .9142-.9150 (23.220-23.240) |
| 9 | 90532-PRO-010 | .9150-.9157 (23.240-23.260) |
| 10 | 90533-PRO-010 | .9157-.9165 (23.260-23.280) |
| 11 | 90534-PRO-010 | .9165-.9173 (23.280-23.300) |
| 12 | 90535-PRO-010 | .9173-.9181 (23.300-23.320) |
| 13 | 90536-PRO-010 | .9181-.9189 (23.320-23.340) |
| 14 | 90537-PRO-010 | .9189-.9197 (23.340-23.360) |
| 15 | 90538-PRO-010 | .9197-.9205 (23.360-23.380) |
| 16 | 90539-PRO-010 | .9205-.9213 (23.380-23.400) |