( TL19E1AE34150200000LDAT00 )

M/T Countershaft Reassembly

Exploded View
Special Tools Required
Inner driver handle, 40 mm
07746-0030100
Inner bearing driver attachment, 30 mm
07746-0030300
NOTE: Refer to the Exploded View, as needed, during this procedure.

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

1. Install the 1st gear distance collar (A) with the needle bearing (B) and the 1st gear (C) onto the countershaft (D).

1. Install the triple cone synchro assembly (A) with the synchro spring (B) by aligning the synchro cone fingers (C) with the grooves (D) in the 1st gear.

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

1. Install the reverse gear (A) by aligning the slots of the reverse gear and the 1st/2nd synchro hub (B). After installing, check the operation of the 1st/2nd synchro hub set.
   NOTE: The slots layout is inequable. Set correctly them.

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

1. Install the 2nd gear distance collar (A) and friction damper (B) by aligning the friction damper fingers (C) with the grooves (D) in the 1st/2nd synchro hub.

1. Install the needle bearing (A).

1. Install the 2nd gear (B) by aligning the synchro cone fingers (C) with the grooves (D) in the 2nd gear.

1. Support the countershaft (A) on steel blocks, then press in the 3rd gear (B) using the 40 mm inner driver handle (C) and a press (D).
   NOTE: Do not exceed the maximum pressure.

1. Press in the 4th gear (A) using the 40 mm inner driver handle (B) and a press (C).
   NOTE: Do not exceed the maximum pressure.

1. Press in the 5th gear (A) using the 40 mm inner driver handle (B) and a press (C).
   NOTE: Do not exceed the maximum pressure.

1. Press in the 6th gear (A) using the 40 mm inner driver handle (B), 30 mm inner bearing driver attachment (C), and a press (D).
   NOTE: Do not exceed the maximum pressure.

1. Install the 35 mm shim (A) and temporary press in the used old ball bearing (B) using the 40 mm inner driver handle (C), 30 mm inner bearing driver attachment (D), and a press (E).
   NOTE:
   - The 35 mm shim are any type that is different its thickness. Note the type of installed shim.
   - Check the ball bearing install direction.

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

   Standard: | 0.04−0.10 mm (0.0016−0.0039 in.)

1. If the measured clearance in Step 15 is without the standard, select another suitable 35 mm shim from the following table, then go to next step to replace the 35 mm shim and the ball bearing with new one. If the measured clearance in Step 15 is within the standard, go to next step to replace the only boll bearing with new one.
   35 mm Shim

   Type | Part Number | Thickness
   --- | --- | ---
   A | 23981-PPP-000 | 0.87 mm (0.034 in.)
   AA | 23981-PPP-900 | 0.91 mm (0.036 in.)
   B | 23982-PPP-000 | 0.95 mm (0.037 in.)
   AB | 23982-PPP-900 | 0.99 mm (0.039 in.)
   C | 23983-PPP-000 | 1.03 mm (0.041 in.)
   AC | 23983-PPP-900 | 1.07 mm (0.042 in.)
   D | 23984-PPP-000 | 1.11 mm (0.044 in.)
   AD | 23984-PPP-900 | 1.15 mm (0.045 in.)
   E | 23985-PPP-000 | 1.19 mm (0.047 in.)
   AE | 23985-PPP-900 | 1.23 mm (0.048 in.)
   F | 23986-PPP-000 | 1.27 mm (0.050 in.)
   AF | 23986-PPP-900 | 1.31 mm (0.052 in.)
   G | 23987-PPP-000 | 1.35 mm (0.053 in.)
   AG | 23987-PPP-900 | 1.39 mm (0.055 in.)
   H | 23988-PPP-000 | 1.43 mm (0.056 in.)
   AH | 23988-PPP-900 | 1.47 mm (0.058 in.)
   J | 23989-PPP-000 | 1.51 mm (0.060 in.)
   AJ | 23989-PPP-900 | 1.55 mm (0.061 in.)
   K | 23990-PPP-000 | 1.59 mm (0.063 in.)
   AK | 23990-PPP-900 | 1.63 mm (0.064 in.)
   L | 23991-PPP-000 | 1.67 mm (0.066 in.)
   AL | 23991-PPP-900 | 1.71 mm (0.067 in.)
   M | 23992-PPP-000 | 1.75 mm (0.069 in.)
   AM | 23992-PPP-900 | 1.79 mm (0.070 in.)
   N | 23993-PPP-000 | 1.83 mm (0.072 in.)
   AN | 23993-PPP-900 | 1.87 mm (0.074 in.)
   P | 23994-PPP-000 | 1.91 mm (0.075 in.)
   AP | 23994-PPP-900 | 1.95 mm (0.077 in.)
   Q | 23995-PPP-000 | 1.99 mm (0.078 in.)

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

1. Repeat Step 13 to install the 6th gear.

1. Install the 35 mm shim (A), and new ball bearing (B) using the 40 mm inner driver handle (C), 30 mm inner bearing driver attachment (D) and a press (E).
   NOTE:
   - If necessary, replace the 35 mm shim to proper one selected in Step 16 .
   - Check the ball bearing installing direction.

1. Check the clearance between the bearing and the 35 mm shim with a feeler gauge.

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

1. Tighten the new special bolt (B) (left-hand threads).
   NOTE: Apply new MTF to the bolt threads and flange.