2. Countershaft and Reverse Idler Gear Replacement

Removal Procedure

^ Tools Required
^ J 34757 Circlip Remover
^ J 22888-30 Puller Legs
^ J 22888-20 Universal Puller





1. Use the J 34757 in order to remove the rear countershaft bearing C-clip (1) from the countershaft.





2. Use the J 22888-20 with the J 22888-30 in order to remove the rear countershaft bearing (2) from the countershaft.





3. Use the J 22912-01 in order to remove the 5th gear (1).





4. Remove the following components from the lower case:
4.1. The reverse idler shaft bolt (1)
4.2. The reverse idler shaft (2)
4.3. The reverse idler gear (3)
5. Remove the following components from the reverse idler shaft:
5.1. The reverse idler gear thrust washer
5.2. The reverse idler gear needle bearing
5.3. The reverse idler gear





6. Remove the following components from the lower case:
^ Two bolts (2)
^ The countershaft center bearing plate (1)





7. Remove the front countershaft bearing C-ring (3) from the front countershaft bearing (2).





8. Use the J 22912-01 in order to remove the reverse gear (1).





9. Use the following procedure in order to remove the countershaft (1) from the lower case:
9.1. Lightly tap the countershaft (1) rearward in the lower case.
9.2. Remove the countershaft center bearing (2) by hand.
9.3. Pull the countershaft forward.
9.4. Remove the countershaft from the lower case.
10. Use the J 34757 in order to remove the front countershaft bearing C-clip from the countershaft.





11. Use the J 22888-20 and the J 22888-30 in order to remove the front countershaft bearing (3) from the countershaft (2).





12. Remove the following components from the countershaft (6):
12.1. The friction gear snap ring (1)
12.2. The friction gear retainer (2)
12.3. The friction gear retainer pin (3)
12.4. The friction gear spring (4)
12.5. The friction gear (5)
13. Clean the following components with solvent:
^ The lower case mating surfaces
^ All of the countershaft components
14. Dry the components thoroughly.
15. Inspect all of the gear tooth surfaces for excessive wear or damage. Inspect the bearings for smooth rotation. Replace the bearings as necessary.

Installation Procedure

^ Tools Required
^ J 37754 Countershaft Bearing Installer
^ J 35664 Bearing Installer
^ J 35871 Countershaft Front Bearing Installer





1. Install the following components onto the countershaft:
1.1. The friction gear
1.2. The friction gear spring
1.3. The friction gear retainer pin
1.4. The friction gear retainer
1.5. The friction gear snap ring
2. Use the J 35871 in order to install the front countershaft bearing (1) onto the countershaft (3).
3. Install the front countershaft bearing C-clip onto the countershaft.





4. Use the following procedure in order to install the following components into the lower case:
^ The countershaft
^ The countershaft center bearing
4.1. Place the countershaft center bearing onto the countershaft.
4.2. Place the countershaft into the lower case.
4.3. Use the J 35664 and the J 37754 in order to press the countershaft and the center bearing (1) into the lower case.





5. Install the front countershaft bearing C-ring (3) onto the front countershaft bearing (2). Position the countershaft so that the front countershaft bearing C-ring (3) makes slight contact with the lower case.
6. Apply Loctite(TM) 414 GM P/N 12345493 or equivalent to the threaded portion of the countershaft center bearing plate bolts.

Notice: Refer to Fastener Notice in Service Precautions.





7. Install the countershaft center bearing plate into the lower case. Secure the countershaft center bearing plate with the two bolts.
^ For vehicles with 4-wheel drive, tighten the countershaft center bearing plate bolts to 10 Nm (89 inch lbs.).
^ For vehicles with 2-wheel drive, tighten the countershaft center bearing plate bolts to 6 Nm (53 inch lbs.).





8. Use the J 37754 and the J 35664 in order to install the rear countershaft bearing (1) onto the countershaft.
9. Install the rear countershaft bearing C-clip onto the countershaft.





10. Install the following components onto the reverse idler shaft (4):
10.1. The reverse idler gear (2,7)
10.2. The reverse idler gear needle bearing (1)
10.3. The reverse idler gear thrust washer
11. Apply Loctite(TM) 414 GM P/N 12345493 or equivalent to the threaded portion of the reverse idler shaft bolt (3).
12. Place the reverse idler gear (2,7) with the reverse idler shaft (4) into the lower case.

Important: Use an aluminum washer on the reverse idler shaft bolt (3). Use of an aluminum washer will seat the reverse idler shaft bolt head without causing damage to the lower case.

13. Secure the reverse idler shaft (4) with one washer and one bolt (3).
^ Tighten the reverse idler shaft bolt to 22 Nm (16 ft. lbs.).





14. Install the countershaft reverse gear (1) onto the countershaft.





15. Install the countershaft 5th gear (1) onto the countershaft.