#
COUNTERSHAFT COMPONENT ASSEMBLY

BHE051117050104

1. Assemble in the order indicated in the table.

2. Verify the following after assembly.

  (1) The gear rotates smoothly when rotated by hand.
  (2) The synchronizer ring is not stuck.

1 | Clutch hub
2 | Synchronizer key
3 | Synchronizer key spring
4 | Steel ball
5 | Clutch hub sleeve
6 | Countershaft gear
7 | Needle bearing
8 | Counter 3rd gear
9 | Inner ring
10 | Middle ring
11 | Synchronizer ring
12 | Clutch hub component (3rd/4th) (See Clutch Hub Component (3rd/4th) Assembly Note.)
13 | Synchronizer ring
14 | Counter 4th gear
15 | Inner race
16 | Thrust washer (See Thrust Washer Assembly Note.)
17 | Retaining ring
18 | Snap ring
19 | Counter drive gear (See Counter Drive Gear Assembly Note.)
20 | Snap ring (friction gear) (See Snap Ring (Friction Gear) Assembly Note.)
21 | Torsion spring
22 | Friction gear
23 | Snap ring
24 | Roller bearing (See Roller Bearing Assembly Note.)
25 | Snap ring (roller bearing) (See Snap Ring (Roller Bearing) Assembly Note.)

## Clutch Hub Component (3rd/4th) Assembly Note

1. Securely align the tabs on each ring of the 3rd gear side with the installation hole of the 3rd gear and the key groove of the clutch hub.

2. Securely align the tab on the synchronizer ring of 4th gear side with the key groove of the clutch hub.

  Caution

  • Do not damage the synchronizer ring when installing the clutch hub component.

3. Carefully install the clutch hub component (3rd/4th) using the SSTs and a press.

## Thrust Washer Assembly Note

1. Install the thrust washer removed during disassembly, and measure the clearance between the thrust washer and the installation groove using a feeler gauge.

2. Select the new thrust washer from the following table so that the clearance measured in Step 1 is within specification, and install it in the countershaft gear with the identification mark facing up.

  Clearance
  0-0.1 mm {0-0.0039 in}

Thrust washer size

mm {in}

Identification mark | Thickness | Identification mark | Thickness
--- | --- | --- | ---
A | 3.75 {0.148} | E | 3.95 {0.156}
B | 3.80 {0.150} | F | 4.00 {0.157}
C | 3.85 {0.152} | G | 4.05 {0.159}
D | 3.90 {0.154} | H | 4.10 {0.161}

## Counter Drive Gear Assembly Note

1. Install the counter drive gear using the SSTs.

## Snap Ring (Friction Gear) Assembly Note

1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge.

2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the countershaft gear.

  Clearance
  0-0.1 mm {0-0.0039 in}

Snap ring size

mm {in}

Identification mark | Thickness | Identification mark | Thickness
--- | --- | --- | ---
A | 1.80 {0.071} | D | 1.95 {0.077}
B | 1.85 {0.073} | E | 2.00 {0.079}
C | 1.90 {0.075} | F | 2.05 {0.081}

## Roller Bearing Assembly Note

1. Install the roller bearing using the SSTs.

## Snap Ring (Roller Bearing) Assembly Note

1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge.

2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the countershaft gear.

  Clearance
  0-0.1 mm {0-0.0039 in}

Snap ring size

mm {in}

Identification mark | Thickness | Identification mark | Thickness
--- | --- | --- | ---
A | 3.75 {0.148} | E | 3.95 {0.156}
B | 3.80 {0.150} | F | 4.00 {0.157}
C | 3.85 {0.152} | G | 4.05 {0.159}
D | 3.90 {0.154} | H | 4.10 {0.161}