Countershaft: Service and Repair

NOTE: For removal and installation procedures refer to "Automatic Transmission/Transaxle, Service and Repair."

COUNTER SHAFT DISASSEMBLY









1. Remove underdrive planetary sun gear from counter shaft.





2. Measure starting torque of counter shaft.
a. Using Special Service Tool (SST) 09350 - 32014 (09351 - 321703) or equivalent, temporarily tighten the lock nut.





b. Using soft jaws, hold the drive pinion in a vise.
c. Using SST 09350 - 32014 (09351 - 32170) and spring tension gauge, measure the starting torque of the counter shaft.
Starting torque:
With spring tension gauge 1.2 - 2.0 kg (2.6 - 4.4 lb)
With torque gauge (hexagon nut side)
- New bearing 0.6 - 1.0 N.m (6 - 10 kgf-cm, 5.2 - 8.7 in. lbf)
- Reused bearing 0.3 - 0.5 N.m (3 - 5 kgf-cm, 2.6 - 4.3 in. lbf)
If the torque is exceeded, replace the spacer.





d. Using Special Service Tool (SST) 09350 - 32014 (09351 - 32170) or equivalent, remove the lock nut.





3. Remove snap ring from sun gear.
Using a snap ring expander, remove the snap ring from the sun gear.





4. Remove snap ring from counter shaft assembly.
Using a screwdriver, remove the snap ring from the counter shaft assembly.





5. Remove underdrive planetary gear.





6. Remove thrust needle roller bearing and race.





7. Remove drive pinion with output flange, bearing, inner race and spacer.
a. Using SST 09950 - 20017, remove the drive pinion with output flange, bearing and inner race.





b. Remove the spacer from the counter shaft.





8. Remove ring gear.
a. Using a screwdriver, remove the snap ring from the counter shaft.





b. Remove the ring gear from the counter shaft.





9. Remove bearing using SST 09950 - 00020 and press.





10. Remove bearing outer races.
Using a brass bar and hammer, tap out both bearing outer races.


COUNTER SHAFT INSPECTION






1. Measure planetary sun gear bushing inside diameter.
Using a caliper gauge, measure the bushing inside diameter of the planetary sun gear.
Standard inside diameter: 29.800 - 29.825 mm (1.1735 - 1.1742 in.)
Maximum inside diameter: 29.870 mm (1.1760 in.)





2. Measure planetary pinion gear thrust clearance.
Using a feeler gauge, measure the planetary pinion gear thrust clearance.
Standard clearance: 0.2 - 0.5 mm (0.008 - 0.020 in.)
Maximum clearance: 0.5 mm (0.020 in.)
If the clearance is greater than the maximum, replace the planetary gear assembly.


COUNTER SHAFT ASSEMBLY






1. Install bearing to counter shaft.
U sing SST 09350 - 32014 (09351 - 32180) and press, press in the bearing of the thick inner race side.
2. Install ring gear.
a. Install the ring gear to the counter shaft.





b. Install the snap ring.





3. Install bearing outer races to drive pinion.
a. Using SST 09350 - 32014 (09351 - 32090, 09351 - 32180) and press, press in the thick race to the flange side of the drive pinion.





b. Using SST 09350 - 32014 (09351 - 32150, 09351 - 32180) and press, press in the thin race to the other side.





4. Install drive pinion to counter shaft.
a. Install a new spacer to the counter shaft.





b. Install the drive pinion to the counter shaft.





5. Install another bearing to counter shaft.
Using SST 09350 - 32014 (09351 - 32180) and press, press in the another bearing.

NOTICE: Be sure there is some clearance between the output flange and bearing.






6. Install bearing inner race.
Using SST 09350 - 32014 (09351 - 32180) and press, press in the inner race.

NOTICE: Be sure there is some clearance.






7. Adjust counter shaft starting torque.
a. Using SST 09350 - 32014 (09351 - 32100) and press, press in the counter driven gear to the counter shaft.





b. install SST 09350 - 32014 (09351 - 32032) to the driven gear.





c. Secure the counter shaft by holding the SST 09350-32014 (093510- 32032) in a vise.





d. Temporarily install the new lock nut, and using SST 09350 - 32014 (09351 - 32170), tighten the lock nut until the counter shaft starting torque is in specification.
Torque (Reference): 177 - 216 N.m (1,800 - 2,200 kgf-cm, 130 - 159 ft.lbf)


HINT: Use a torque wrench with a fulcrum length of 42 cm (16.54 in.).






e. Using soft jaws, hold the drive pinion in a vise.
f. Using SST 09350 - 32014 (09351 - 32170) and spring tension gauge, measure the starting torque of the counter shaft.
Starting torque:
with tension gauge 1.2 - 2.0 kg (2.6 - 4.4 lb)
with torque gauge (hexagon nut side)
- New bearing 0.6 - 1.0 N.m (6 - 10 kgf-cm, 5.2 - 8.7 in.lbf)
- Reused bearing 0.3 - 0.5 N.m (3 - 5 kgf-cm, 2.6 - 4.3 in. lbf)
If the starting torque is exceeded, replace the spacer and retorque.

HINT: Before measuring the starting torque, snug down the bearing by turning the counter shaft.






g. Using a punch and hammer, stake the lock nut.





h. Remove SST 09350 - 32014 (09351 - 32032) from the counter driven gear.




i. Using SST 09350 - 32014 (09351 - 32061), remove the counter driven gear.





8. Install race and bearing.
Coat the race and bearing with petroleum jelly and install them to the counter shaft.
Bearing mm (in.)
- Outer diameter: 43.85 (1.726)
- Inner diameter: 31.0 (1.220)
Race mm (in.)
- Outer diameter: 41.8 (1.646)
- Inner diameter: 30.0 (1.181)





9. Install underdrive planetary gear.
a. Install the underdrive planetary gear to the counter shaft.





b. Install the snap ring.





10. Install underdrive planetary sun gear.
a. Using a snap ring expander, install the snap ring to the sun gear.





b. Install the underdrive planetary sun gear to the counter shaft.