Countershaft Gear & Drive Pinion

Fig. 6 Countergear Replacement:

1. Lubricate countershaft gear bore and install roller bearing spacer with dummy shaft into gear. Center the spacer and dummy shaft.
2. Install 19 rollers, a spacer ring, 19 more rollers and spacer ring into gear.
3. Lubricate and install new thrust washers, if needed, on dummy shaft with tanged side facing toward case boss.
4. Place countershaft gear assembly on bottom of case, Fig. 6.
5. Press drive pinion bearing onto pinion shaft with outer snap ring groove facing front of transmission. Fully seat the bearing against gear shoulder.
6. Install new bearing retaining snap ring.
7. With pinion shaft held in a soft jawed vise, install 16 roller bearings in shaft cavity. Coat bearings with heavy grease and install bearing retaining snap ring in groove.
8. On all except overdrive units:
a. Install drive pinion and bearing assembly through rear of case and position in front bore. Tap into place with a mallet and install outer snap ring in bearing groove.
b. Insert countershaft in bore at rear of case and raise the countershaft gear until the teeth mesh with drive pinion gear. Ensure thrust washers remain properly positioned.
c. Align dummy shaft with case bores, then push countershaft into gear. Tap shaft into case until shaft end is flush with case surface. remove dummy shaft.
9. On all units, install new oil seal in retainer bore.