Upper Countershaft Disassembly and Reassembly
Precautions: Precautions for Diagnosing Trouble · Precautions for Disassembly and Reassembly · Precautions for Transmission / Transaxle · General safety (00)
CAUTION:
Using an inappropriate hydraulic press or bearing puller could cause personal injury.
Use the hydraulic press and bearing puller which are capable of safely bearing a load of at least 5 tons (11,000 lbs).
NOTICE:
Supporting the gear on the concave side of the puller can cause damage to the gear.
Support the gear on the flat side of the puller.
Disassembly
NOTE:
The upper countershaft bolt is of a left-handed thread type pre-coated with adhesive.
Therefore, turn clockwise when removing it.
However, adhered bolt with adhesive requires higher loosening torque than specified tightening torque.
1)Engage reverse gear (1) with 5th & reverse gear synchronizer sleeve (2).
2)Hold reverse gear with soft jawed vise and blocks (3) securely.
3)Remove upper countershaft bolt (4).
4)Remove upper countershaft left bearing (1) with reverse gear (2) using special tool and hydraulic press.
5)Remove reverse gear needle bearing (1).
6)Remove reverse gear spacer (1) with 5th & reverse gear synchronizer sleeve & hub (2), 5th gear (3), 5th gear spacer, 5th gear needle bearing, 2nd gear washer and 2nd gear (4) at the same time using special tool and hydraulic press.
7)Remove 2nd gear needle bearing (1).
8)Remove 2nd gear spacer (1) with 2nd & 4th gear synchronizer sleeve & hub (2) and 4th gear (3) at the same time using special tool and hydraulic press.
9)Remove 4th needle bearing (1).
10)Remove circlip (1) using snap ring pliers (2).
11)Remove upper countershaft right bearing (1) using hydraulic press.
12)Remove upper countershaft plug (1) from lower countershaft (3) using flat-bladed screwdriver (2) or the like and hammer.
Reassembly
1)To ensure lubrication of upper countershaft (1), blow air into oil holes (2) and check that they are free from any obstruction.
2)Install new upper countershaft plug (1) using special tool and hammer.
3)Install new upper countershaft right bearing (1) using special tools and hydraulic press.
4)Select new circlip as follows.
a)Measure clearance “a” between groove (1) of upper countershaft and upper countershaft right bearing (2) with feeler gauge (3).
b)Select a circlip closest to the clearance “a” from the following available sizes.
Available circlip thickness
| Clearance “a” | Select circlip |
|---|---|
| 2.500 – 2.530 mm (0.0984 – 0.0996 in.) |
2.500 mm (0.0984 in.) |
| 2.530 – 2.560 mm (0.0996 – 0.1008 in.) |
2.530 mm (0.0996 in.) |
| 2.560 – 2.590 mm (0.1008 – 0.1020 in.) |
2.560 mm (0.1008 in.) |
| 2.590 – 2.620 mm (0.1020 – 0.1031 in.) |
2.590 mm (0.1020 in.) |
| Over 2.620 mm (0.1031 in.) | 2.620 mm (0.1031 in.) |
5)Install new circlip (1) using snap ring pliers (2).
6)Install 4th gear needle bearing (1) and apply oil to it.
7)Fit 2nd & 4th gear synchronizer sleeve (1) to hub (2), and insert 3 keys (3) as shown in figure.
NOTE:
No specific direction is assigned to 2nd & 4th gear synchronizer sleeve or each key but it is assigned as assembly.
Synchronizer key installation position
| [A]: | 2nd gear side | B: | Key way |
8)Install 4th gear (1) with 2nd & 4th gear synchronizer sleeve & hub (2) using special tools and hydraulic press.
NOTE:
Check that synchronizer ring key slots are aligned with keys (3) while press-fitting sleeve & hub assembly.
| [A]: | 2nd gear side |
10)Install 2nd needle bearing (1) and apply oil to it.
11)Install 2nd gear (1) and 2nd gear washer (2).
13)Install 5th gear needle bearing (1) and apply oil to it.
14)Fit 5th & reverse gear synchronizer sleeve (1) to hub (2), and insert 3 keys (3) as shown in figure.
NOTE:
No specific direction is assigned to 5th & reverse gear synchronizer sleeve or each key but it is assigned as assembly.
Synchronizer key installation position
| [A]: | Reverse gear side | B: | Key way |
15)Install 5th gear (1) with 5th &reverse gear synchronizer sleeve & hub (2) using special tools and hydraulic press.
NOTE:
Check that synchronizer ring key slots are aligned with keys (3) while press-fitting sleeve & hub assembly.
| [A]: | Reverse gear side |
17)Install reverse gear needle bearing (1) and apply oil to it.
18)Install reverse gear (1).
19)Install upper countershaft left bearing (1) using special tool and hydraulic press.
20)Engage reverse gear (1) with 5th & reverse gear synchronizer sleeve (2).
21)Hold reverse gear with soft jawed vise and blocks securely as shown.
22)Install new upper countershaft bolt (3) and tighten it to specified torque.
NOTICE:
The upper countershaft bolt is pre-coated with adhesive. If the bolt is reused, it may work loose.
Use the new upper countershaft bolt.
23)After replacing transaxle inner parts, perform TCM and Clutch Initialization.