Countershaft Assembly

Before disassembling the countershaft assembly inspect for wear and damage, and make the following measurements:

- If any measurement is out of tolerance, the countershaft assembly must be disassembled and spacer collars or the thrust washer changed.




1. Measure clearance between the thrust washer and the 1st gear.




2. Measure clearance between the 28 mm spacer and 2nd gear.




3. Measure the clearance between the 26 mm thrust washer and the 3rd gear.




4. Measure clearance between 4th gear and the flanged spacer.
5. If measurements are within tolerance, and gears are not worn or damaged, the countershaft need not be disassembled.




6. If any measurements are out of tolerance, figure the additional thickness required to bring each clearance back within service limit. Then reinstall both mainshaft and countershaft assemblies in clutch housing, temporarily reinstall the transmission housing, and install mainshaft holder.




7. Raise the tab countershaft locknut using a hammer and pick punch. Remove locknut using a 32 mm socket at least 55 mm (2.2 in.) deep, and a breaker bar.




8. Remove the transmission housing, and pull gear assemblies out of clutch housing, then disassemble the countershaft assy.




9. Based on the what you figured in step 6; select the correct thrust washer or spacer collar listed.




10. After countershaft has been reassembled, place both countershaft and mainshaft back in clutch housing; reinstall transmission housing and mainshaft holder, then torque countershaft locknut to 90 N.m (65 lb-ft), loosen, and retighten to same torque.
11. Disassemble the transmission and recheck clearances. If clearances are in tolerance, stake shoulder on locknut with center punch.