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Old 03-06-2009, 12:31 AM   #4
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Re: 94 Metro 5 Speed Manual Transmission Rebuild - PART 2 - Assembly

........Countershaft Assembly........

The manual says to install the R Bearing Cone first. (Number on Bearing is 33005)

Here is the Countershaft end sticking up thru a File Cabinet Folder with a hole in it
on top of a paper towel Roll - to help hold the bugger so's I can photograph it !

The R Roller Thrust Bearing Cone has a thin metal cage around the rollers and this
is quite fragile - as I found out when I was taking the old one off.

In order to protect it, they use another "Special Tool" !

I found that a 1/2 inch washer (1.25 inches diameter) fits inside the cage and is high
enough to allow me to press down on the Bearing center without hurting the surrounding roller cage.

So - I set up my Gear and Bearing Puller again (the long threaded rods allow me to
do just about anything!) and pressed the bearing onto the Countershaft.

Went on really nice - no problems.

Here is shown how the Washer sticks up above the Bearing Cage - I was able to
spin the bearing as I was pressing it on !

The Washer stopped the Gear and Bearing Puller right exactly at the top edge of the Countershaft - just as it should be....Nice.

I labeled the OLD R Bearing Sleeve (End Race) and covered the Bearing with it just to protect the Rollers whilst I work on the rest of the Shaft.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Put in the 1st Gear Needle Bearings, oiled them, then pushed on the 1st Gear.

The 1st Gear Synchronizer Ring is supposed to be different than the 2nd Gear
Synchronizer Ring...

Manual (Page 7A - 26 Bottom of page) says the "Key Slot" sizes are

1st Gear Synchronizer Ring Key slot = 8.2 mm (0.32 in)

2nd Gear Synchronizer Ring Key slot = 9.6 mm (0.38 in)

The Kit has both with the 8.2 mm (0.32 in) size. .....?

Wrote an E-Mail to the E-Bay Seller asking if they screwed the pooch....

Here is the answer (quoted)....... dated 3-6-2009


Itís how we supply our kit and its no mistake, use the synchros.
The slot widths make no difference unless itís too narrow for the keys.
This has been proven over time many times.
We sell the same ring for 1st & 2nd

Thank you for being so careful

Randy Laskowsky
866-223-5656 Toll Free"

So...I will take Randy at his word and proceed along the path to finishing this assembly.

Everything else in the Kit has been "A-OK" and things are, as NASA would say, "Nominal" - going according to plan.


Last edited by DOCTORBILL; 03-06-2009 at 12:18 PM.
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