Countershaft

1. Place the third countershaft gear on the bench with the synchro clutch ring up.

Fig. 82:

2. Install the third countershaft gear friction cone onto third gear.

NOTE: The area between the locating tabs on the friction cone alternate between being high and low areas. The area between the locating tab recesses on the third countershaft gear clutch ring have matching high and low areas. Ensure that the high area between the locating tabs on the friction cone are located to the high areas between the recesses on clutch ring.

Fig. 83:

3. Install the third countershaft gear blocker ring onto the friction cone.

Fig. 84:

4. Install the 3-4 synchro assembly onto the blocker ring/gear assembly.
5. Reverse the assembly on the bench.
6. Install the third countershaft gear bearing into the third countershaft ear.
7. Install the 2-3 thrust washer onto the third gear/3-4 synchro assembly.
8. Move the third gear/3-4 synchro assembly to a suitable shop press.
9. Install the countershaft through the third gear/ 3 synchro assembly.

Fig. 85:

10. Using the shop press, press the countershaft into the 3-4 synchro assembly.
11. Install the fourth countershaft gear bearing sleeve onto the output shaft.
12. Using Installer 8228 and a suitable shop press, press the fourth countershaft bearing sleeve onto the countershaft.
13. Place the fourth countershaft gear on the bench with the synchro clutch ring up.
14. Install the fourth countershaft gear friction cone onto fourth countershaft gear.

NOTE: The area between the locating tabs on the friction cone alternate between being high and low areas. The area between the locating tab recesses on the fourth countershaft gear clutch ring have matching high and low areas. Ensure that the high area between the locating tabs on the friction cone are located to the high areas between the recesses on clutch ring.

15. Install the fourth countershaft gear blocker ring onto the friction cone.
16. Install the fourth countershaft gear bearing into the fourth countershaft gear.
17. Position the sixth countershaft gear in the shop press.

Fig. 86:

18. Position the fourth countershaft gear assembly onto the sixth countershaft gear.
19. Install the countershaft into the fourth/sixth countershaft gear assembly in the shop press.

Fig. 87:

20. Using the shop press, press the countershaft into sixth gear.
21. Position the fifth countershaft into the shop press.
22. Install the countershaft into the fifth countershaft gear.

Fig. 88:

23. Using the shop press, press the countershaft into fifth gear.