Lower Case, Countershaft and Reverse Idler Gear

REMOVE OR DISCONNECT
^ Tools Required:
- J 34757 Circlip Remover
- J 22888-20 Universal Puller
- J 22888-30 Puller Legs





1. Rear countershaft bearing C-clip from countershaft using J 34757.





2. Rear countershaft bearing from countershaft using J 22888-20 with the J 22888-30.
3. Countershaft 5th gear and reverse gear from countershaft, one at a time by hand.





4. Reverse idler shaft bolt, reverse idler shaft and reverse idler gear from lower case.
5. Reverse idler gear thrust washer, reverse idler gear needle bearing and reverse idler gear from reverse idler shaft.





6. Two bolts and countershaft center bearing plate from lower case.





7. Front countershaft bearing C-ring from front countershaft bearing.





8. Lightly tap the countershaft rearward in the lower case and remove the countershaft center bearing by hand. Then, pull the countershaft forward and remove it from the lower case.
9. Front countershaft bearing C-clip from countershaft using J 34757.





10. Front countershaft bearing from countershaft using J 22888-20 with J 22888-30.
11. Friction gear snap ring, friction gear retainer, friction gear retainer pin, friction gear spring and friction gear from countershaft.

Clean
- Lower case mating surfaces and all countershaft components with solvent and dry thoroughly.

Inspect
- All gear tooth surfaces for excessive wear or damage and bearings for smooth rotation. Replace as necessary.

INSTALL OR CONNECT
^ Tools Required:
- J 37754 Countershaft Bearing Installer
- J 35664 Bearing Installer
- J 35871 Countershaft Front Bearing Installer

1. Friction gear, friction gear spring, friction gear retainer pin, friction gear retainer and friction gear snap ring onto countershaft.





2. Front countershaft bearing onto countershaft using J 35871.
3. Front countershaft bearing C-clip onto countershaft.





4. Countershaft center bearing onto countershaft and countershaft into lower case by pressing countershaft and center bearing into lower case using J 35664 with J 37754.
5. Front countershaft bearing C-ring onto front countershaft bearing and position countershaft so that the front countershaft bearing C-ring makes light contact with the lower case.
6. Apply Loctite(tm) 414, or equivalent, to the threaded portion of the countershaft center bearing plate bolts.
7. Countershaft center bearing plate into lower case; secure with two bolts.
- Tighten countershaft center bearing plate bolts to 6 Nm (53 inch lbs.).
8. Reverse idler gear, reverse idler gear needle bearing and reverse idler gear thrust washer onto reverse idler shaft.
9. Apply Loctite (tm) 414, or equivalent, to the threaded portion of the reverse idler shaft bolt.





10. Reverse idler gear with reverse idler shaft into lower case; secure with one washer and one bolt.

Important: An aluminum washer must be used on the reverse idler shaft bolt to seat the reverse idler shaft bolt head without causing damage to the lower case.

- Tighten reverse idler shaft bolt to 22 Nm (16 ft. lbs.).
11. Countershaft reverse gear and countershaft 5th gear onto countershaft.





12. Rear countershaft bearing onto countershaft using J 37754 with J 35664.
13. Rear countershaft bearing C-clip onto countershaft.