Countershaft Assembly
NOTE: A press with 40,000 lbs. capacity is required to service countershaft.Disassemble
1. Place countershaft in a soft jawed vice, heat front bearing race with a propane torch enough to allow movement toward end of countershaft using a hammer and chisel around flanged edge of bearing race.
2. Press front bearing remaining distance with press using split plate tool No. J 22912-01 or equivalent.
3. Remove snap ring from countershaft, them press 4th speed counter gear from countershaft using split plate tool No. J 22912-01 or equivalent.
4. Press 3rd counter gear and 6th gear from countershaft using split plate tool No. J 36513 or equivalent.
5. Remove 6th gear needle bearing assembly, then snap ring.
6. Press 6th gear synchronizer ring from 5-6 synchronizer body.
7. Remove synchronizer sleeve. When removing synchronizer sleeve use a shop towel wrapped around sleeve to prevent detent ball from becoming lost.
8. Remove pressure pieces, synchronizer detent balls, then synchronizer detent springs.
9. Press 5-6 synchronizer body from and 5th gear from countershaft using split plate tool No. J 36513 or equivalent.
10. Remove 5th gear synchronizer ring and 5th gear needle bearing assembly.
Assemble
1. Place countershaft threaded end up in a press.
2. Press 5th gear needle assembly and 5th gear with synchronizer teeth facing up.
3. Install 5-6 synchronizer ring onto taper of 5th gear.
4. Press 5-6 synchronizer body onto countershaft using tool No. J 36184 and tube driver tool No. J 36183 or equivalents. Synchronizer body must be heated to 176°F for 10-15 minutes before pressing onto countershaft.
5. Install snap ring onto countershaft. Snap ring is available in three sizes, 0.112, 0.116 and 0.120 inches. Select thickest snap ring that will seat fully into snap ring groove.
6. Install synchronizer detent springs 0.600 inches long into pressure pieces and insert pairs into detent bores of synchronizer. Detent springs must face towards the reamed teeth of 5-6 synchronizer sleeve.
7. Install 5-6 synchronizer sleeve onto synchronizer body. Push sleeve flush against 5th countergear.
8. One at a time, pull back pressure pieces far enough to place detent balls onto detent springs, then insert pressure pieces back into sleeve and body
9. Install 6th gear synchronizer ring. The three stop cams of 6th gear synchronizer ring must point to respective recesses of synchronizer body.
10. Install 6th gear bearing assembly and 6th gear onto countershaft.
11. Press 3rd and forth counter gear, one at a time, onto countershaft until fully seated. Gears must be heated to 300°-350°F for 45 minutes before pressing onto countershaft. Raise collars of gears must face each other.
12. Install snap ring onto countershaft, then press countershaft front bearing inner race onto countershaft using tool Nos. J 5590 tube driver and adapter J 37278 or equivalents. Inner race must be heated to 176°F before pressing onto countershaft.
13. Position countershaft assembly into support and assembly fixture engaging countershaft gear teeth with output shaft gear teeth.