Component Disassembly & Reassembly: Countershaft: Reassembly
- To check countershaft 2nd gear clearance, install all components on countershaft up to the reverse selector hub. See Figure. DO NOT install "O" rings on countershaft at this time.
- Install reverse selector hub on countershaft in proper direction. Support countershaft in press. Press reverse selector hub onto countershaft.
- Install countershaft reverse gear collar on countershaft. See Figure. DO NOT install reverse selector, countershaft reverse gear and needle bearing on countershaft at this time.
- Install transaxle housing bearing on countershaft. Install countershaft 1st gear collar, needle bearing and countershaft 1st gear with one-way clutch and parking gear on countershaft. See Figure.
- Install spring washer and used countershaft lock nut on countershaft. Tighten countershaft lock nut to 22 ft. lbs. (30 N.m).
- Using feeler gauge, measure countershaft 2nd gear clearance between distance collar and countershaft 2nd gear. See Fig 1. Measure countershaft 2nd gear clearance in 3 areas. Determine the average of the measurements. Countershaft 2nd gear clearance should be .002-.005" (.05-.13 mm).
- If countershaft 2nd gear clearance is not within specification, install different length distance collar between countershaft 2nd gear and countershaft 4th gear and recheck clearance. See DISTANCE COLLAR SPECIFICATIONS table.
- If shortest distance collar is installed and clearance still exceeds specification, check components for wear. During final reassembly, lubricate all components with Dexron-II ATF.
- Before installing NEW "O" rings on countershaft, wrap splines with tape. Ensure NEW "O" rings are installed on countershaft.
- Ensure reverse selector hub is installed on countershaft in proper direction. See Figure. Ensure thrust needle bearings and needle bearings are installed with unrolled edge of bearing retainer facing washer surface.
DISTANCE COLLAR SPECIFICATIONS
| Collar Number | Part Number | Thickness In. (mm) |
|---|---|---|
| 1 | 90503-PC9-000 | 1.535 (39.00) |
| 2 | 90504-PC9-000 | 1.539 (39.10) |
| 3 | 90505-PC9-000 | 1.543 (39.20) |
| 4 | 90507-PC9-000 | 1.547 (39.30) |
| 5 | 90508-PC9-000 | 1.537 (39.05) |
| 6 | 90509-PC9-000 | 1.541 (39.15) |
| 7 | 90510-PC9-000 | 1.545 (39.25) |
| 8 | 90511-PC9-000 | 1.531 (38.90) |
| 9 | 90512-PC9-000 | 1.533 (38.95) |