Disassembly And Assembly: Countershaft

DISASSEMBLY

Courtesy of CHRYSLER GROUP, LLC

Part

1 - Front Bearing

2 - Reverse Gear

3 - First Gear

4 - Second Gear

5 - Rear Bearing Race

6 - 1/2 Synchronizer

7 - Reverse Synchronizer

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

Courtesy of CHRYSLER GROUP, LLC

1 - Front Case Bearing Snap Ring
Place the reverse synchronizer sleeve toward the 1st gear to provide space to support the gear for removal.

Courtesy of CHRYSLER GROUP, LLC

1 - Reverse Synchronizer Sleeve

Using the puller special tool # 1130, (Bearing/Gear Splitter) and a press, place the splitter under the reverse gear and press the shaft using special tool # 8253, (Seal Installer) 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.

Courtesy of CHRYSLER GROUP, LLC

1 - Reverse Gear

2 - Installer, Seal 8253

3 - Splitter, Bearing/Gear 1130

Remove the reverse gear needle bearing and the synchronizer assembly from the shaft assembly.

Courtesy of CHRYSLER GROUP, LLC

1 - Reverse Gear Needle Bearing

2 - Reverse Gear Synchronizer Assembly
Remove the needle bearing spacer and the snap ring retaining 1st gear.

Courtesy of CHRYSLER GROUP, LLC

1 - Needle Bearing Spacer

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

Courtesy of CHRYSLER GROUP, LLC

1 - 1st gear

2 - Splitter, Bearing/Gear 1130
Remove the 1st gear needle bearing.

Courtesy of CHRYSLER GROUP, LLC

1 - 1st Gear Needle Bearing
Remove the needle bearing spacer and snap ring retaining the 1-2 synchronizer.

Courtesy of CHRYSLER GROUP, LLC

1 - Needle Bearing Spacer

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

Courtesy of CHRYSLER GROUP, LLC

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

Courtesy of CHRYSLER GROUP, LLC

1 - 2nd Gear Needle Bearing
Remove the snap ring retaining the case bearing inner race.

Courtesy of CHRYSLER GROUP, LLC

1 - Case Bearing Inner Race Snap Ring

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.

Courtesy of CHRYSLER GROUP, LLC

1 - Puller 1023

2 - Thrust Button 6055

3 - Case Bearing Inner Race

ASSEMBLY

Courtesy of CHRYSLER GROUP, LLC

1 - Case Bearing Inner Race

2 - Installer, Bearing W-262

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

Courtesy of CHRYSLER GROUP, LLC

1 - Case Bearing Inner Race Snap Ring (Selective)
Install 2nd gear needle bearing on the shaft.

Courtesy of CHRYSLER GROUP, LLC

1 - 2nd Gear Needle Bearing
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, (Bearing Installer) 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.

Courtesy of CHRYSLER GROUP, LLC

1 - 2nd Gear

2 - Installer, Bearing D-389
Due to manufacturing tolerances, install a NEW , LARGEST selective snap ring that fits into the groove. Install the needle bearing thrust washer.

Courtesy of CHRYSLER GROUP, LLC

1 - Needle Bearing Thrust Washer

2 - 2nd Gear Snap Ring (Selective)
Install the 1st gear needle bearing. Apply specified oil to needle bearing.

Courtesy of CHRYSLER GROUP, LLC

1 - 1st Gear Needle Bearing
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, (Bearing Installer) and a press, press the reverse hub on the countershaft.

Courtesy of CHRYSLER GROUP, LLC

1 - Reverse Hub

2 - Installer, Bearing W-262
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.
NOTE:
Reverse gear synchronizer assembly.

Courtesy of CHRYSLER GROUP, LLC

1 - Reverse Gear Needle Bearing

2 - Reverse Synchronizer Ring And Sleeve

Courtesy of CHRYSLER GROUP, LLC

1 - Needle Bearing Thrust Washer

2 - Reverse Hub Snap Ring (Selective)
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.

Courtesy of CHRYSLER GROUP, LLC

1 - Reverse Synchronizer Key

2 - Reverse Synchronizer Key Spring
Using special tool # W-262, (Bearing Installer) 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.

Courtesy of CHRYSLER GROUP, LLC

1 - Front Case Bearing

2 - Installer, Bearing W-262
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.

Courtesy of CHRYSLER GROUP, LLC

1 - Front Case Bearing Snap Ring (Selective)