Countershaft

Countershaft








Special Tool(s)

Disassembly





1. Place the special tool in a vise, then install the countershaft with the countershaft locknut facing upward. Loosen the countershaft locknut. Do not remove at this time.

2. NOTE: Place the Bearing/Oil Seal Plate in a vise.

Install the countershaft in the bearing/oil seal plate with the countershaft bearing facing upward.





3. Using the special tools, remove the countershaft bearing.
^ Install new bearings and cups in a set only. Do not install one without the other.





4. Remove the spacer.





5. Remove the countershaft third gear.
^ Inspect the gear for wear or damage. Install a new gear as necessary.





6. Remove the countershaft second gear.
^ Inspect the gear for wear or damage. Install a new gear as necessary.





7. Remove the second gear needle bearing and the needle bearing inner race.
^ Inspect the bearing for wear or damage. Install a new bearing as necessary.





8. Remove the first and second gear synchronizer assembly.





9. Disassemble the first and second gear synchronizer assembly.
^ Inspect the synchronizer for wear or damage. Repair or install a new synchronizer as necessary.




10. Remove the countershaft first gear.
^ Inspect the gear for wear or damage. Install a new gear as necessary.





11. Remove the first gear needle bearing.
^ Inspect the bearing for wear or damage. Install a new bearing as necessary.
12. Rotate the countershaft in the bearing/oil seal plate.





13. Remove the countershaft locknut.





14. Using the special tools, remove the countershaft front bearing.
^ Install new bearings and cups in a set only. Do not install one without the other.





15. Remove the countershaft fifth gear.
^ Inspect the gear for wear or damage. Install a new gear as necessary.





16. Remove the fifth gear needle bearing.
^ Inspect the bearing for wear or damage. Install a new bearing as necessary.





17. Remove the synchronizer blocking ring.





18. Remove the thrust washer.





19. Remove the two piece thrust washer.





20. Remove the fifth/reverse synchronizer body.





21. Disassemble the fifth/reverse synchronizer assembly.
^ Inspect the synchronizer for wear or damage. Repair or install a new synchronizer as necessary.





22. Remove the synchronizer blocking ring.





23. Remove the countershaft reverse gear.
^ Inspect the gear for wear or damage. Install a new gear as necessary.





24. Remove reverse gear needle bearing.
^ Inspect the bearing for wear or damage. Install a new bearing as necessary.

25. CAUTION: To prevent damage, inspect the surface of the countershaft in the area of the bearing race to make sure it is smooth and free of burrs.

Inspect the countershaft for damage or wear. Install a new shaft as necessary.

Assembly

1. CAUTION: Do not reassemble the countershaft dry. Apply lubricant throughout the assembly procedure.

Lubricate all countershaft components with the recommended transmission lubricant.





2. Position the countershaft in the special tool.





3. Install the reverse gear needle bearing.





4. Install the countershaft reverse gear.





5. Install the reverse synchronizer blocking ring.
^ The reverse synchronizer blocking ring has a carbon surface.





6. Install the fifth/reverse synchronizer assembly.
^ Make sure to align the notches on the synchronizer body with the tabs on the synchronizer ring.





7. Install the fifth synchronizer blocking ring.
The fifth synchronizer blocking ring is brass.





8. Install the two piece thrust washer.





9. Install the thrust washer.





10. Install the fifth gear needle bearing.





11. Install the countershaft fifth gear.





12. Using the special tools, install the countershaft front bearing.





13. Install the countershaft locknut.





14. Reposition the countershaft in the bearing/oil seal plate.





15. Install the first gear needle bearing.





16. Install the countershaft first gear.





17. Assemble the first and second gear synchronizer assembly.





18. Install the first and second gear synchronizer assembly.
^ Move the synchronizer sliding sleeve to the center position.





19. Install the needle bearing inner race and the second gear needle bearing.





20. Install the countershaft second gear.





21. Install the countershaft third gear.





22. Install the spacer.





23. Install the countershaft bearing.

24. NOTE: The transmission must be in the neutral position before final assembly.

Make sure to position the synchronizer sliding sleeves in the neutral position.