Countershaft

Special Tool(s)

	Handle 205-153 (T80T-4000-W)
	Installer, Shift Rail Needle Bearing 308-130 (T87T-7025-DH)
	Puller, Bearing 205-D064 (D84L-1123-A) or equivalent

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Disassembly

NOTICE: Hand-tighten the Bearing Puller to prevent gear damage.

NOTICE: Support the countershaft while using the hydraulic press to prevent damage to the shaft or gears.

1. Using the Shift Rail Needle Bearing Installer, Handle, Bearing Puller and a hydraulic press, remove the 5th gear.
   • Inspect the 5th gear for wear or damage. Install a new gear as necessary.

2. Using the Shift Rail Needle Bearing Installer, Bearing Puller and a hydraulic press, remove the 6th gear.
   • Inspect the 6th gear for wear or damage. Install a new gear as necessary.

3. Remove the 3rd gear.
   • Inspect the 3rd gear for wear or damage. Install a new gear as necessary.

4. Remove the 3rd gear needle bearing.
   • Inspect the 3rd gear needle bearing for wear or damage. Install a new needle bearing as necessary.

5. NOTE: Prior to removing the synchronizer rings, note the position of each synchronizer ring.

   Remove the 3rd gear synchronizer ring assembly.
   • Inspect all synchronizer ring components for wear or damage. Install new components as necessary.

6. Remove the 3rd/4th gear synchronizer assembly snap ring.

7. Using the Shift Rail Needle Bearing Installer, the Bearing Puller and a hydraulic press, remove the 4th gear and the 3rd/4th gear synchronizer assembly.

8. NOTE: Prior to removing the synchronizer rings, note the position of each synchronizer ring.

   Remove the 4th gear from the 4th gear synchronizer ring assembly. Remove the 4th gear synchronizer ring assembly from the 3rd/4th gear synchronizer assembly.
   • Inspect the 4th gear for wear or damage. Install a new gear as necessary.
   • Inspect the 3rd/4th gear synchronizer assembly for wear or damage. Install a new 3rd/4th gear synchronizer assembly as necessary.
   • Inspect the synchronizer ring components for wear or damage. Install new components as necessary.

9. NOTICE: When removing the bearing, do not over expand the bearing cage or damage to the bearing cage can occur.

   Remove the 4th gear needle bearing.
   • Inspect the 4th gear needle bearing for wear or damage. Install a new needle bearing as necessary.

10. Inspect the countershaft for scoring or worn or damaged splines. Install a new countershaft as necessary.

Assembly

NOTICE: Lubricate all components with the recommended transmission fluid before assembling.

1. NOTICE: When installing the bearing, do not over expand the bearing cage or damage to the bearing cage can occur.

   Install the 4th gear needle bearing.

2. NOTICE: The groove on the 3rd/4th gear synchronizer assembly must be facing away from 4th gear or damage to the synchronizer assembly can occur.

   NOTICE: The 6 synchronizer ring tabs must engage into the 6 gear slots and the 3 synchronizer ring tabs must engage into the 3 synchronizer assembly slots or damage to the synchronizer assembly and synchronizer ring assembly can occur.

   NOTE: The 4th gear synchronizer ring assembly outer ring has one identification notch.

   With the groove on the 3rd/4th gear synchronizer assembly sleeve facing away from 4th gear install the 4th gear synchronizer ring assembly and the 4th gear.
   • Align the 6 synchronizer ring tabs with the 6 gear slots and the 3 synchronizer ring tabs with the 3 synchronizer assembly slots.

3. Using the Bearing Puller and a hydraulic press, install the 4th gear and the 3rd/4th gear synchronizer assembly.

4. Install the 3rd/4th gear synchronizer assembly snap ring.

5. NOTICE: The 6 synchronizer ring tabs must engage into the 6 gear slots or damage to the synchronizer assembly and synchronizer ring assembly can occur.

   NOTE: The 3rd gear synchronizer ring assembly outer ring has 2 identification notches.

   Position the 6th gear and the 3rd gear and the 3rd gear synchronizer ring assembly onto the Bearing Puller.
   • Align the 6 synchronizer ring tabs with the 6 gear slots.

6. NOTE: Lubricate the needle bearing with petroleum jelly to hold it in place during assembly.

   Install the 3rd gear needle bearing.

7. NOTICE: The 3 synchronizer ring tabs must engage into the 3 synchronizer assembly slots or damage to the synchronizer assembly and synchronizer ring assembly can occur.

   NOTICE: Do not allow the 3rd gear needle bearing to slide down the countershaft while pressing the components or damage to the needle bearing can occur.

   While keeping the 3rd gear needle bearing from sliding down the countershaft, use the Bearing Puller and a hydraulic press, install the 6th gear the 3rd gear and the 3rd gear synchronizer ring assembly.
   • Align the 3 synchronizer ring tabs with the 3 synchronizer assembly slots.

8. Using the Bearing Puller and a hydraulic press, install the 5th gear.