Countershaft 2nd Gear and 5th Gear Axial Clearance Inspection

Special Tools Required 

Driver Handle, 40 mm I.D. 07746-0030100

1. Slide the park gear (A) over the countershaft (B).
   Fig 1: Identifying Park Gear And Countershaft

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2. Place the park gear (A) on press bases (B), and place a spacer (C) between the countershaft (D) and the press to prevent damaging the countershaft.
   Fig 2: Placing Park Gear On Press Bases And Place Spacer Between Countershaft

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3. Install the park gear using a press.
4. Install the 53 x 57 x 20 mm needle bearing (A), 1st gear (B), 5th gear (C), the 42.5 x 52.5 x 2.5 mm thrust washer (D), the 5th gear collar (E), the 42.5 mm thrust shim (F), and 2nd gear (G) on the countershaft (H). Install 2nd gear and 5th gear in the direction shown.
   Fig 3: Identifying Needle Bearing, 1st Gear, 5th Gear, Thrust Washer, Gear Collar, Thrust Shim, And 2nd Gear On Countershaft

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5. Install the ball bearing (A) over the countershaft (B), then press it into place using the 40 mm I.D. driver handle and the press.
   Fig 4: Identifying Ball Bearing And Countershaft

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6. Secure the final drive gear part of the countershaft in a bench vise with wood blocks, install the old lock bolt (A), and tighten it to 125 N.m (12.7 kgf.m, 92 lbf.ft). The lock bolt has left-hand threads.
   NOTE: After this procedure, remove wood chips that may be stuck to the gear.
   Fig 5: Installing Lock Bolt

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7. Measure the clearance between the 5th gear collar (A) and the 42.5 mm thrust shim (B) with a feeler gauge (C) in at least three places. Use the average as the actual clearance.

   Standard: 0.04 - 0.10 mm (0.002 - 0.003 in) 

   Fig 6: Measuring Clearance Between 5th Gear Collar And Thrust Shim With Feeler Gauge

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8. If the clearance is out of the standard, remove the 42.5 mm thrust shim and measure its thickness.
9. Select and install a new 42.5 mm thrust shim, then recheck the clearance.
   THRUST SHIM, 42.5 MM
   
   

   No.	Thickness
   A	1.82 mm (0.0717 in)
   B	1.86 mm (0.0732 in)
   C	1.90 mm (0.0748 in)
   D	1.94 mm (0.0764 in)
   E	1.98 mm (0.0780 in)
   F	2.02 mm (0.0795 in)
   G	2.06 mm (0.0811 in)
   H	2.10 mm (0.0827 in)
   I	2.14 mm (0.0843 in)
   J	2.18 mm (0.0858 in)
   K	2.22 mm (0.0874 in)
   L	2.26 mm (0.0890 in)