Intermediate Plate: Service and Repair

DISASSEMBLY
1. Disassemble in the order indicated in the illustration, referring to the following steps.





2. Remove the reverse idler gear shaft installation bolt.
3. Support the reverse idler gear shaft, and press it out from the bearing housing.
4. Support the mainshaft front bearing, and press it out from the bearing housing by using a pipe with an outer diameter of 70.0 mm (2.76 inch).

NOTE: If Countershaft center bearing is replaced, replace the spacer also.

5. Support the Countershaft center bearing, and press it out from the bearing housing by using a pipe with an outer diameter of 50.0 mm (1.97 inch).

ASSEMBLY
1. Assemble in the reverse order of disassembly indicated in the illustration, referring to the following.
2. Measure the clearance between the Countershaft center bearing and the bearing housing. If not within 0 - 0.1 mm (0 - 0.004 inch), adjust the clearance by installing the correct adjustment shim(s). Adjustment shim sizes 0.1 mm (0.004 inch), 0.3 mm (0.012 inch).
3. Press the Countershaft center bearing into the bearing housing with pipe with an outer diameter of 50.0 mm (1.97 inch).
4. Measure the clearance between the mainshaft front bearing and the bearing housing. If not within 0 - 0.1 mm (0 - 0.004 inch), adjust the clearance by installing the correct adjustment shim(s). Adjustment shim sizes 0.1 mm (0.004 inch), 0.15 mm (0.006 inch), 0.3 mm (0.012 inch).
5. Press the mainshaft front bearing into the bearing housing with a pipe with an outer diameter of 70.0 mm (2.76 inch).
6. Press the reverse idler gear shaft into the bearing housing.
7. Install and tighten the reverse idler gear shaft installation bolt to 9 - 12 Nm (79 - 112 inch lbs.).
8. Install the reverse idler gear, end washer, and bearing cover.





9. Tighten the bearing cover installation bolts. Tightening torque:
^ A: 18 - 26 Nm (14 - 19 ft. lbs.)
^ B: 37 - 53 Nm (27 - 39 ft. lbs.)