Countershaft Assembly

Countershaft Assembly

Component Identification: Countershaft






Apply Transmission lubricant to each piece as it is assembled

Combine Step 1 thru 5




1. Get the 3rd/4th Clutch Hub




2. Insert the 3-Synchronizer Keys into the hub




3. Insert the 3-Synchronizer Key Springs into the keys




4. Place the 3-Steel Balls onto the springs
- Hold 2-balls with the index finger and thumb of one hand and the 3rd with your other index finger










5. Press the balls inward against spring pressure
- Determine which direction the hub and sleeve should face
- Place the sleeve on top of the hub
- Align the notches of the sleeve with the keys of the hub
- Slide the sleeve over the hub




6. Get the Countershaft Gear




7. Install the 3rd gear split Needle Bearing
8. Install Countershaft 3rd Gear




9. Install the 4th Synchronizer Ring













10. Place the 3rd/4th Clutch Hub onto the Countershaft
- Align the tabs in the Synchronizer Ring with the notches in the Clutch Hub
- Keep the Synchronizer Ring properly aligned while pressing the Hub onto the shaft
- Use SST 49-F401-331 (part of kit SST49- F401-330B) and SST 49-M005-796

(In this picture the Synchronizer Ring is being held in the correct position as it is pressed onto the shaft)




11. Install 4th Synchronizer Ring




12. Install the Countershaft 4th Gear







13. Install the Inner Race
- Twist the race and the gear as you install them so they seat all the way on the countershaft
- After Step 11 to 13 align all of the parts













14. Install the Selective Thrust Washer removed during disassembly
- Use feeler gauges to measure the clearance between the old Thrust Washer and the groove
- Add the feeler gauge thickness to the Snap-Ring thickness
- Use the chart to select the correct thrust washer so that the clearance is standard
- Replace the Thrust Washer with a new one even if the old Snap-Ring is the correct size
- Remove the old Thrust Washer and install the new Thrust Washer




15. Install the Retaining Ring




16. Install a new Snap-Ring




17. Use SST 49-N017-104 and SST 49- M005-796
- Install the Countershaft Drive Gear













18. Install the correct Friction Gear Snap- Ring removed during disassembly into its groove
- Measure the clearance between the Snap Ring and the groove
- Add the feeler gauge thickness to the Snap-Ring thickness
- Use the chart to select the correct Snap-Ring so that the clearance is standard
- Replace the Snap-Ring with a new one even if the old Snap-Ring is the correct size
- Remove the old Thrust Washer and install the new Thrust Washer




19. Install the Torsion Spring




20. Install the Friction Gear
- The spring goes through a small hole




21. Install the spacer



















22. Install the 3-piece roller Bearing to the Countershaft
- Install the inner race first (Note the side with writing faces the gear)
- Install the outer race with the bearings in the center
- Install the center race
- Press on the Bearing with SST 49-H025- 004 and SST 49-M005-796
- Hold the Bearing races in position while pressing the pieces on













23. Install the Selective Snap-Ring (Countershaft Front Bearing) removed during disassembly into its groove
- Measure the clearance between the Snap- Ring and the groove
- Add the feeler gauge thickness to the Snap- Ring thickness
- Use the chart to select the correct Snap-Ring so that the clearance is standard
- Replace the Snap Ring with a new one even if it is the correct size