Disassembly And Assembly: Countershaft

WARNING: This page is about a different variant/trim than selected.

DISASSEMBLY

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PART IDENTIFICATION

Callout	Part
1.	Front Bearing
2.	Reverse Gear
3.	First Gear
4.	Second Gear
5.	Rear Bearing Race
6.	1-2 Synchronizer
7.	Reverse Synchronizer

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1 - Front Case Bearing Snap Ring

Using a suitable tool, remove the snap ring from the shaft holding the front case bearing.

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1 - Reverse Synchronizer Sleeve

Place the reverse synchronizer sleeve toward the 1st gear to provide space to support the gear for removal.

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1 - Reverse Gear

2 - Installer, Seal 8253

3 - Splitter, Bearing/Gear 1130

Using the puller (special tool #1130, Splitter, Bearing/Gear) and a press, place the splitter under the reverse gear and press the shaft using (special tool #8253, Installer, Seal) to remove the bearing and reverse gear. Be sure to support the countershaft to prevent it from damage when the bearing and reverse gear separate from the countershaft.

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1 - Reverse Gear Needle Bearing

2 - Reverse Gear Synchronizer Assembly
Remove the reverse gear needle bearing and the synchronizer assembly from the shaft assembly.

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1 - Needle Bearing Spacer

2 - 1st Gear Snap Ring
Remove the needle bearing spacer and the snap ring retaining 1st gear.

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1 - 1st gear

2 - Splitter, Bearing/Gear 1130
Using the puller (special tool #1130, Splitter, Bearing/Gear) and a press, support the 1st gear assembly with the bearing splitter and press the shaft to remove the gear.

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1 - 1st Gear Needle Bearing
Remove the 1st gear needle bearing.

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1 - Needle Bearing Spacer

2 - 1-2 Synchronizer Snap Ring
Remove the needle bearing spacer and snap ring retaining the 1-2 synchronizer.

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1 - 2nd Gear
With a suitable tool supporting 2nd gear and a press, press the shaft to remove the 1-2 synchronizer and 2nd gear assemblies.

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1 - 2nd Gear Needle Bearing
Remove the 2nd gear needle bearing from the assembly.

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1 - Case Bearing Inner Race Snap Ring

Remove the snap ring retaining the case bearing inner race.

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1 - Puller 1023

2 - Thrust Button 6055

3 - Case Bearing Inner Race

Using (special tool #1023, Puller) in the two jaw orientation, press on the (special tool #6055, Thrust Button), to remove the case bearing inner race from the assembly.

ASSEMBLY

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1 - Case Bearing Inner Race

2 - Installer, Bearing W-262

Using a suitable support tool, a press and (special tool #W-262, Installer, Bearing), support the shaft and press case bearing inner race on the countershaft.

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1 - Case Bearing Inner Race Snap Ring (Selective)
Due to manufacturing tolerances, install a NEW , LARGEST selective snap ring that fits into the groove. Be sure to tap the ends of the snap ring to fully seat.

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1 - 2nd Gear Needle Bearing
Install 2nd gear needle bearing on the shaft.

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1 - 2nd Gear

2 - Installer, Bearing D-389
Install 2nd gear and 2nd gear synchronizer rings to assembly. Be sure the synchronizer fingers are located properly in the hub and gear to prevent damage. Using the (special tool #D-389, Installer, Bearing) and a press, support the 1-2 synchronizer hub (deep side of hub towards rear, deep step of sleeve towards front), and press the shaft until hub is in place.

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1 - Needle Bearing Thrust Washer

2 - 2nd Gear Snap Ring (Selective)
Due to manufacturing tolerances, install a NEW , LARGEST selective snap ring that fits into the groove. Install the needle bearing thrust washer.

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1 - 1st Gear Needle Bearing
Install the 1st gear needle bearing. Apply specified oil to needle bearing.

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1 - Reverse Hub

2 - Installer, Bearing W-262
Install 1st gear and 1st gear synchronizer rings to assembly. Be sure the synchronizer fingers are located properly to prevent damage. Using (special tool #W-262, Installer, Bearing) and a press, press the reverse hub on the countershaft.

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1 - Needle Bearing Thrust Washer

2 - Reverse Hub Snap Ring (Selective)
Due to manufacturing tolerances, install a NEW , LARGEST selective snap ring that fits into the groove. Be sure to tap the ends of the snap ring to fully seat. Install the needle bearing thrust washer.

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1 - Reverse Synchronizer Key

2 - Reverse Synchronizer Key Spring

NOTE:
Reverse gear synchronizer assembly.

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1 - Reverse Gear Needle Bearing

2 - Reverse Synchronizer Ring And Sleeve
Install the reverse gear needle bearing. Apply specified oil to needle bearing. Install reverse synchronizer ring and sleeve to assembly. Be sure the synchronizer fingers are located properly to prevent damage.

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1 - Front Case Bearing

2 - Installer, Bearing W-262
Using (special tool #W-262, Installer, Bearing) and a press, install the front case bearing (snap ring groove towards the end) to the countershaft. Be sure to push the bearing on by the inner race ONLY to prevent damage to the bearing.

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1 - Front Case Bearing Snap Ring (Selective)
Due to manufacturing tolerances, install a NEW , LARGEST selective snap ring that fits into the groove. Be sure to tap the ends of the snap ring to fully seat.