E. Countershaft Overhaul

REMOVE OR DISCONNECT

^ Tool Required:
- J 22912-01 Split Plate

NOTICE: Observe the hydraulic pressure gage during countershaft disassembly. Pressure on the countershaft and its components should not exceed 4990 kg (11,000 lbs.). If pressure higher than specified is needed for countershaft disassembly, the countershaft may be misaligned in the press support. Reset the press and press support before resuming countershaft disassembly or damage to the countershaft and its components may occur.





1. Left countershaft bearing and countershaft 4th gear from the countershaft using a J 22912-01 and a press arbor.





2. 3rd and 4th gear spacer with countershaft 3rd gear and countershaft 2nd gear from the countershaft using the J 22912-01 and a press arbor.
3. 2nd gear synchronizer ring from countershaft.





4. Low speed synchronizer snap ring from countershaft.





5. Low speed sleeve and hub together with 1st gear synchronizer ring and countershaft 1st gear from countershaft using the J 22912-01 and a press arbor.
6. Low speed sleeve from the low speed hub.
7. Low speed synchronizer spring from the low speed hub.
8. 1st and 2nd gear bearing from countershaft.





9. Right countershaft bearing from the countershaft using the J 22912-01, a press arbor extension and a press arbor.

Clean
- All components thoroughly with clean solvent and dry. If using compressed air to dry parts, DO NOT spin dry bearings or damage to the bearings may result.

Inspect
- Countershaft for flat spots, excessive wear or damage. Replace as necessary.





- Countershaft oil passages for obstructions by applying compressed air into the end of the countershaft. If air does not flow freely out of the countershaft oil the countershaft.
- All bearings for roughness, locking or damage. Replace as necessary.
- All gears for cracks, chipped or broken teeth or other damage. Replace as necessary.
- All synchronizer components for chipped or broken teeth, excessive wear or damage. Replace as necessary.





Measure
1. Clearance between the 1st gear synchronizer ring and countershaft 1 st gear using a feeler gage. Standard clearance is 1.0 to 1.4 mm (0.039 to 0.055 inch). If clearance is below 0.5 mm (0.019 inch), replace the 1 st gear synchronizer ring and countershaft 1st gear.
2. Clearance between the 2nd gear synchronizer ring and countershaft 2nd gear using a feeler gage. Standard clearance is 1.0 to 1.4 mm (0.039 to 0.055 inch). If clearance is below 0.5 mm (0.019-inch), replace the 2nd gear synchronizer ring and countershaft 2nd gear.

INSTALL OR CONNECT

^ Tools Required:
- J 34846 Countershaft Bearing Installer
- J 35664 Press Tube/Bearing Installer
- J 37754 Countershaft Bearing Installer
- J 36850 Transjel Transmission Assembly Lubricant

1. Apply a thin coat of J 36850 to all parts prior to assembly.





2. Right countershaft bearing onto countershaft using a J 34846 and a hammer.
3. 1st and 2nd gear bearing onto countershaft.





4. Low speed synchronizer spring onto the low speed hub.
5. Low speed sleeve onto the low speed hub.





Important
- The key slot width of the 1st gear synchronizer ring is smaller than that of the 2nd gear synchronizer ring. The difference in key slot width must be distinguished for correct countershaft assembly. If these synchronizer rings are transposed during countershaft assembly, shift failure may occur.





6. Countershaft 1st gear, 1st gear synchronizer ring and low speed sleeve and hub onto countershaft using the J 34846 for support, a J 35664 and a press arbor.

Inspect
- Countershaft 1st gear for smooth rotation after low speed sleeve and hub installation. If countershaft 1st gear does not rotate smoothly, remove gear and reinstall it until smooth rotation is obtained.





7. Low speed synchronizer snap ring onto countershaft.
8. 2nd gear synchronizer ring onto countershaft.

Important
- To prevent undue stress on the countershaft, install the countershaft 2nd gear and counter-shaft 3rd gear first, then install the 3rd and 4th gear spacer separately.





9. Countershaft 2nd gear and countershaft 3rd gear onto the countershaft using the J 34846 for support, the J 35664 with a J 37754 and a press arbor, then the 3rd and 4th gear spacer onto the countershaft using the J 34846 for support, the J 35664 with the J 37754 and a press arbor.





10. Countershaft 4th gear and left countershaft bearing onto the countershaft using the J 34846 for support, the J 35664 and a press arbor.