Countershaft

COUNTERSHAFT

DISASSEMBLY





1. Remove the transmission.
2. Disassemble the geartrain housing.
3. Remove the snap ring (1).





4. Press off the constant mesh gear (2) and the 6th gear drive gear (3).
5. Clamp the countershaft in a vise with protective jaws with the output end pointing downwards.





6. Remove the 3rd gear idler gear (1) and needle bearing (2).





7. Remove the 3rd/4th gear clutch body (1) and the friction ring (2).





8. Remove the 3rd/4th gear cone ring (1), the synchronizer ring (2), and the locking ring (3) using pliers.





9. Use the jaw puller to remove the 4th gear (2) together with the 3rd/4th gear synchronizer (1).





10. Remove the 4th gear synchronizer ring (1), cone ring (2), and friction ring (3).





11. Remove the 4th gear clutch body (1), gear (2), and needle bearing (3).
12. Release the countershaft from the vise.

ASSEMBLY
1. Clamp the countershaft in a vise with input end up.





2. Install the 4th gear needle bearing (3), gear (2), and clutch body (1).





3. Install 4th gear friction ring (3), cone ring (2), and synchronizer ring (1).
4. Unless a new synchronizer is being used, the synchronizer unit must be properly assembled.





5. Install the 4th gear (2) and the 3rd/4th gear synchronizer unit (1).





6. Install the snap ring (3), the 3rd/4th gear synchronizer ring (2), and cone ring (1).





7. Install the friction ring (2), and clutch body (1).





8. Install the 3rd gear needle bearing (2), and 3rd gear idler gear (1).





9. Install the 6th gear drive gear (3) and press onto the countershaft.
10. Install the constant mesh gear (2) and press onto the countershaft.
11. Install a new snap ring (1).
12. Remove the countershaft from the vise.
13. Assemble the gear train housing.
14. Install the transmission.