Countershaft Disassembly

Countershaft Disassembly

Component Identification: Countershaft






Photocopy this images for use during repairs

Measure all Countershaft Gear thrust clearances
You can use either:




- A dial indicator

Or










- Feeler gauges

Countershaft Gear Radial Clearance Inspection










- Place the countershaft in a vice with jaw protectors
- Use a dial indicator
- Excess clearance indicates a bearing, shaft or gear problem
- Record any parts that need replacement on the Repair Order







1. Remove the Countershaft front Bearing Snap-Ring
- Measure the Snap-Ring thickness
- Record the measurement on the Selective Snap- Ring sheet (see of the Introduction)
- Place the Snap-Ring on the Selective Snap-Ring Sheet (see of the Introduction)







2. Get SST 49-H027-002
- Remove the Countershaft Roller Bearing
- Use a press arbor in the center At least 0.85 inches wide and 1.5 inches tall (about the same size as a 1/2inch drive 19mm short impact socket)
- Don't let the shaft fall
- The Bearing will come off in three pieces:
1. The center race
2. The outer race with bearings
3. The inner race




3. Remove the Spacer




4. Remove the Friction Gear




5. Remove the Torsion Spring







6. Remove the Friction Gear Selective Snap-Ring
- Measure the Snap-Ring
- Write its thickness on the Selective Snap-Ring sheet (see of the Introduction)
- Place the Snap-Ring on the Selective Snap-Ring sheet (see of the Introduction)







7. Get SST 49-N017-102
- Remove the Countershaft Drive Gear




8. Remove the 4th gear Snap-Ring
Discard the Snap-Ring, it must be replaced with a new one




9. Remove the Retaining Ring




10. Remove the split Thrust Washer
- Measure and record its thickness on the Selective Snap-Ring sheet
- Place the Thrust Washer on the Selective Snap- Ring sheet

Combine Step 11 and 12




11. Remove the Inner Race and
12. The Countershaft 4th Gear
- Twist the gear counterclockwise to remove the assembly




13. Remove the 4th gear Synchronizer Ring

Combine Step 14 thru 17




14. Use SST 49-G030-370
- Remove Counter Shaft 3rd Gear and 3rd / 4th synchronizer hub
- Place the 3rd / 4th Synchronizer Hub into the bag marked 3rd / 4th

15. Clutch Hub Component 3rd / 4th
- Place the clutch hub in the bag marked 3rd /4th




16. Synchronizer Ring
17. Split Needle Bearing







18. Inspect the Countershaft Runout
- Use V-blocks and
- a dial indicator
- Record any parts that need replacement on the Repair Order

Combine Step 19 thru 23







19. Keep the 3rd/4th Clutch Hub in its marked bag:
- Remove the sleeve from the hub while inside the bag

Make sure you have all of the pieces:
- 3-Steel Balls {part #20}
- 3-Synchronizer Key Springs {part # 21}
- 3-Synchronizer Keys {part #22}










23. The Clutch Hub is bare
Inspect the 3rd and 4th gear synchronizer rings for wear
- Use feeler gauges
- If a synchronizer ring is not at specifications, replace the synchronizer ring
- Record any parts that need replacement on the Repair Order