Exploded View

Fig 1: Exploded View Of Countershaft

Special Tools Required 

• Driver 07749-0010000
• Attachment 42 x 47 mm 07746-0010300
• Seal driver 07947-6890100

1. Clean all the parts in solvent, dry them, and apply lubricant to all contact surfaces.
2. Install the needle bearing (A) onto the countershaft (B). Assemble the friction damper (C) and 1st gear (D) together and install them on the countershaft, then install the synchro ring (E) and the synchro spring (F).
   Fig 2: Installing Needle Onto Countershaft

   
3. Install the 1st/2nd synchro hub (A) by aligning the fingers on the friction damper (B) with 1st/2nd synchro hub grooves.
   Fig 3: Installing 1st/2nd Synchro Hub

   
4. Install reverse gear, 2nd gear synchro spring, and the double cone synchro assembly.
5. Install the friction damper (A) on the spacer (B) using the special tools and a press.
   Fig 4: Installing Friction Damper On Spacer

   
6. Install the friction damper and spacer, and the 2nd gear bearing.
7. Install 2nd gear (A) by aligning the synchro cone fingers (B) with 2nd gear grooves (C).
   Fig 5: Installing 2nd Gear Aligning Synchro Cone Fingers With 2nd Gear Grooves

   
8. Install 3rd gear, 4th gear, and 5th gear.
9. Install the needle bearing (A) and the ball bearing (B) using the special tool and a press (C).
   Fig 6: Installing Needle Bearing & Ball Bearing

   
10. Install the spring washer (A), and loosely install the new locknut (B).
    Fig 7: Installing Spring Washer

    
11. Securely clamp the countershaft assembly in a bench vise with wood blocks.
12. Torque the new locknut to 108 N.m (11 kgf.m, 79lbf.ft), then loosen it and torque it again to the same value. Stake the locknut tab into the groove.