Lower Case

Disassemble

Fig. 4 Rear Bearing Removal:

Fig. 5 Reverse Idler Gear Assembly Removal:

Fig. 6 Bearing Plate Assembly:

1. Remove countershaft circlip using removal tool J34757 or equivalent.
2. Remove rear bearing using puller tool Nos. J-22888 and J-22888-35, Fig. 4.
3. Remove 5th gear and reverse gear, Fig. 4.
4. Remove idler gear shaft attaching bolt, Fig. 5, then the reverse idler gear assembly.
5. Remove bearing plate, Fig. 6.
6. Remove circlip from front bearing using suitable tool.
7. Using a suitable plastic hammer, tap countershaft free in lower case.
8. Remove countershaft center bearing from countershaft.
9. Remove countershaft from lower case, then the circlip from countershaft using removal output shaft ring remover tool No. J34757 or equivalent.
10. Remove front bearing using suitable puller.

Inspection
Check the countershaft and bearings for excessive wear or damage, and ensure bearings rotate properly. Replace worn or damaged components as necessary.

Assemble

Fig. 7 Countershaft Bearing Installation:

1. Install countershaft in lower case.
2. Install outer circlip on front bearing using suitable tool.
3. Support lower case and countershaft, then install front bearing on countershaft, Fig. 7.
4. Install circlip on countershaft.
5. Support lower case assembly so countershaft can move downward freely, then install front bearing in lower case, Fig. 7, until circlip is flush with case.
6. Install center bearing using bearing installation tool Nos. J37754 and J35664 or equivalent.
7. Install bearing plate and attaching bolts. Torque attaching bolts to 7.5 ft. lbs. Apply Loctite to threads of attaching bolts.
8. Install reverse idler gear assembly, washer and attaching bolt, Fig. 5. Torque bolt to 16 ft. lbs. To prevent damage to lower case, ensure attaching bolt washer is aluminum.
9. Install 5th gear on countershaft.
10. Support countershaft and install rear bearing using installation tool Nos. J35664 and J37754 or equivalent.
11. Install circlip on countershaft.