Countershaft Gear Assembly; Cleaning And Inspection - Jeep J-10 Series 1982 Technical & Service Manual

THRUST
WASHER
COUNTERSHAFT
GEAR
COUNTERSHAFT
<L
o
/
BEARING
RETAINER
NEEDLE
BEARINGS (42)
Fig. 2B-59 Countershaft Gear Assembly
90631
(2) Remove third-fourth synchronizer assembly
from mainshaft. Slide hub out of sleeve. Remove insert
springs and three inserts and blocking ring. Note posi
tion of insert springs for assembly reference.
(3) Remove third gear from mainshaft.
(4) Remove second gear snap ring from mainshaft
and remove second gear and blocking ring.
(5) Remove tabbed thrust washer from mainshaft
(fig. 2B-60).
(6) Remove snap ring from first-second synchro
nizer hub. Remove hub and reverse gear and sleeve as
assembly. Mark hub and sleeve for assembly reference.
Remove insert springs from hub, remove three inserts,
and remove sleeve and gear from hub.
(7) Remove first gear thrust washer from rear of
shaft and remove first gear and blocking ring (if ring
was not removed previously).
CLEANING AND INSPECTION
Cleaning
Thoroughly wash all parts in solvent and dry using
compressed air. However, do not dry the bearings with
compressed air. Air dry the bearings or wipe them dry
using a clean shop cloth only.
Clean the needle and clutch shaft roller bearings by
wrapping the bearings in a clean cloth and submerging
them in solvent. Or, place the bearings in a shallow
parts cleaning tray and cover them with solvent. Allow
the bearings to air dry on a clean cloth.
Inspection
Inspect the transmission components. Replace any
components that exhibit the following conditions:
Case
Cracks in bores, sides, bosses or at bolt holes.
Stripped threads in bolt holes.
MANUAL TRANSMISSION 2B-29
•Nicks, burrs, rough surfaces in shaft bores or on
gasket surfaces.
Gear. Shaft and Synchronizer Assemblies
• Broken, chipped or worn gear teeth.
•Damaged splines on mainshaft, synchronizer hubs,
or sleeves.
• Broken or worn teeth or excessive wear or damage of
blocking rings.
• Bent or broken synchronizer inserts.
• Damaged needle bearings or bearing bores in reverse
idler or countershaft gear.
• Wear or galling of mainshaft, countershaft, clutch
shaft or idler gear shafts.
• Worn thrust washers.
•Nicked, broken, or worn mainshaft or clutch shaft
splines.
• Bent, distorted, broken or weak snap rings.
• Rough, galled, worn, or broken front or rear bearing.
ASSEMBLY
(1) Lubricate reverse idler gear shaft bore and slid
ing gear with transmission lubricant. Install sliding
gear on reverse idler gear (fig. 2B-58).
(2) Install Arbor Tool J-29343 in reverse idler gear
and install 22 needle bearings and one bearing retainer
at each end of gear (fig. 2B-61).
(3) Coat reverse idler gear thrust washer surfaces
with petroleum jelly and install thrust washers in case.
NOTE: The thrust washers have fiats on them. Be sure
to install the washers so these fiats will face the main-
shaft. Also, be sure to engage the thrust washer locating
tabs in the case locating slots.
(4) Install reverse idler gear assembly (fig. 2B-62).
Align gear bore, thrust washers, case bores, and install
reverse idler gear shaft from rear of case. Be sure to seat
roll pin in shaft, align roll pin with counterbore in case
and push shaft into rear of case (fig. 2B-57).
(5) Measure reverse idler gear end play by inserting
feeler gauge between thrust washer and gear. End play
should be 0.004 to 0.018 inch (0.10 to 0.45 mm). If end
play exceeds 0.018 inch (0.45 mm), remove idler gear and
replace thrust washers.
(6) Coat counter shaft gear bore, needle bearings
and bearing bores in gear with petroleum jelly. Insert
arbor tool in bore of gear and install 21 needle bearings
and one retainer in each end of gear.
(7) Coat countershaft gear thrust washer surfaces
with petroleum jelly and position thrust washers in
case.
NOTE: Be sure to engage the locating tabs on the
thrust washers in the locating slots in the case.
(8) Insert countershaft into rear case bore just far
enough to hold rear thrust washer in position. This will