J. Countershaft Assembly

Measure

- Tool Required:
- J 37271 Countershaft Locknut Spanner Wrench





- Countershaft drive pinion bearing preload (countershaft starting torque) before disassembly using a J 37271 and torque wrench. Place the countershaft drive pinion in a soft jaw vise and turn the countershaft front lock nut with a J 37271 and a torque wrench. Countershaft should require approximately 0.6 to 1.0 Nm (5.3 to 8.8 ft. lbs.) to rotate. If countershaft drive pinion bearing preload does not fall within specification, inspect countershaft assembly components for excessive wear.

REMOVE OR DISCONNECT

- Tools Required:
- J 37271 Countershaft Locknut Spanner Wrench
- J 36513 Large Bearing Split Plate
- J 22912-01 Bearing Split Plate





1. Underdrive planetary carrier snap ring from countershaft drive pinion.





2. Underdrive planetary carrier from countershaft drive pinion.





3. Underdrive sun gear outer thrust bearing and race from countershaft.





4. Countershaft front roller bearing inner races countershaft outer drive pinion bearing and countershaft drive pinion from countershaft using a J 37273 with a J 36513 and a hydraulic press.
5. Crush sleeve from countershaft.





6. Underdrive planetary ring gear snap ring and underdrive planetary ring gear from underdrive planetary ring gear flange on countershaft.





7. Countershaft inner drive pinion bearing from countershaft using a J 37273 with a J 22912-01 and a hydraulic press.





8. Countershaft inner drive pinion bearing race from countershaft drive pinion using a standard drift punch and a hammer.





9. Countershaft outer drive pinion bearing race from countershaft drive pinion using a standard drift punch and a hammer.

Clean
- All countershaft assembly components and dry thoroughly.

Inspect
1. All countershaft assembly bearings and races for rough operation, excessive wear or damage. Replace as necessary.
2. Countershaft drive pinion gear and parking gear for chipped or broken teeth, excessive wear or damage. Replace countershaft drive pinion as necessary.
3. Underdrive planetary ring gear for excessive wear or damage. Replace as necessary.
4. Underdrive planetary carrier for excessive wear or damage. Replace as necessary.
5. Underdrive sun gear for excessive wear or damage. Replace as necessary.

Measure

- Tool Required:
- J 26900-6 Dial Caliper





1. Underdrive sun gear flange bushing inside diameter using a J 26900-6. Standard underdrive sun gear flange bushing inside diameter should fall within 29.800 to 29.825 mm (1.1735 to 1.1742 inch). Maximum sun gear flange bushing inside diameter is 29.870 mm (1.1760 inch). If underdrive sun gear flange bushing inside diameter is greater than specified, replace the underdrive sun gear.





2. Underdrive planetary carrier pinion gear thrust clearance using a feeler gage. Standard underdrive planetary carrier pinion gear thrust clearance should fall within 0.2 to 0.5 mm (0.008 to 0.020 inch). If underdrive planetary carrier pinion gear thrust clearance is greater than 0.5 mm (0.020 inch), replace the underdrive planetary carrier.

INSTALL OR CONNECT

- Tools Required:
- J 37271 Countershaft Locknut Spanner Wrench
- J 35287 Countershaft Bearing Race Installer
- J 8092 Driver Handle
- J 37287 Countershaft Inner Race Support Disc





1. Countershaft inner drive pinion bearing race into countershaft drive pinion using a J 35287 with a J 8092 and a hammer.





2. Countershaft outer drive pinion bearing race into countershaft drive pinion using a J 35287 with a J 8092 and a hammer.





3. Countershaft inner drive pinion bearing onto countershaft using a J 37278 and a hydraulic press.
4. Underdrive planetary ring gear onto underdrive planetary ring gear flange on countershaft; secure with underdrive planetary ring gear snap ring.
5. New crush sleeve onto countershaft.

Important: In order to achieve true and accurate countershaft drive pinion bearing preload, the countershaft drive pinion must be rotated during the installation of the countershaft drive pinion bearing to ensure that the new crush sleeve is not collapsed before countershaft drive pinion bearing preload can be adjusted. It is recommended that the countershaft drive pinion and outer drive pinion bearing be installed first and then the countershaft front roller bearing inner race. This is to allow the technician to rotate the countershaft drive pinion during outer drive pinion bearing installation. If the countershaft drive pinion will not rotate, or is hard to rotate after outer drive pinion bearing installation, the crush sleeve has been collapsed and must be replaced with a new crush sleeve.











6. Countershaft drive pinion and outer drive pinion bearing onto countershaft using a J 37287 and a hydraulic press while rotating countershaft drive pinion. Then, press countershaft front roller bearing inner race onto countershaft using a J 37287 and a hydraulic press, making sure a small space exists between countershaft front roller bearing inner race and outer drive pinion bearing.





7. Underdrive sun gear outer thrust bearing and race onto countershaft.





8. Underdrive planetary carrier into countershaft drive pinion.
9. Underdrive planetary carrier snap ring into countershaft drive pinion.





10. Front countershaft locknut onto countershaft. Do not tighten fully.

Adjust

- Tools Required:
- J 37271 Countershaft Lock Nut Spanner Wrench
- J 34826 Hub Nut Wrench
- J 37273 Countershaft Pressing Button

1. Countershaft drive pinion bearing preload (countershaft starting torque) using a J 37271 and a torque wrench.





A. Temporarily install the countershaft driven gear onto the countershaft using a hydraulic press (Figure 198).
B. Temporarily install the countershaft driven gear locknut onto the countershaft using a J 34826.
C. Place the countershaft assembly in a soft jaw vise holding the countershaft assembly by the countershaft driven gear locknut.





D. Tighten the front countershaft locknut gradually in increments of 5 Nm (44 ft. lbs.) using a J 37271. Between each increment of tightening, remove the countershaft assembly from the soft vise and place the countershaft drive pinion in the soft jaw vise so that the countershaft is able to rotate.





E. Measure countershaft drive pinion bearing preload (countershaft starting torque) using a J 37271 and a torque wrench between each increment of tightening. Countershaft should require approximately 0.6 to 1.0 Nm (5.3 to 8.8 ft. lbs.) for new bearings or 0.3 to 0.5 Nm (2.6 to 4.3 ft. lbs.) for reused bearings to rotate. If countershaft drive pinion bearing preload does not fall within specification, inspect countershaft assembly components for excessive wear.
F. Remove countershaft drive pinion from soft jaw vise.
G. Remove countershaft driven gear locknut using a J 34826.





H. Remove countershaft driven gear from countershaft using a J 37273 and a hydraulic press.





2. Stake front countershaft locknut