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21-1 6
TRANSMISSION?-SPEED
MANUAL
not locking in gear, install a new part. Inspect the
shift forks for wear on the shanks and pads.
Synchronizer Stop Rings
Inspect the stop rings for cracks at the corners of
the shift plate indexing slots. If the rings are cracked
or show signs of extreme wear on the threaded bore,
install new rings at reassembly.
Mainshah
Inspect the mainshaft gear and bearing mating
sur-
faces. If the gear contact surfaces show signs of gall-
ing or excessively worn, a new mainshaft should be
installed.
Inspect the snap ring grooves for burred edges. If
rough or burred, remove the condition using a fine
file or crocus cloth. Inspect the synchronizer clutch
gear teeth on the shaft for burrs.
ASSEMBLY
Countershaft Gear
To reassemble the transmission, refer to (Fig. 19 or
20),
then proceed as follows:
(1)
A-903:
Install the spring, "anti-backlash" plate
and snap ring on the countershaft gear (Fig. 34).
Make sure the snap ring is well seated and that the
plate does not bind or stick in one position.
With the plate against the stop pin, the gear
teeth should be plainly visible between any two teeth
on the plate. If adequate clocking is not obtainable in
either direction, enlarge the pin hole in the plate
with
a
round file.
(2) Slide the countershaft gear bearing roller spac-
er over arbor Tool C-578 for
A-903 transmission or
(2-3834 for A-745 transmission. Coat the bore of the
gear with lubricant and slide the tool and spacer in
the gear bore.
NK312
Fig. 34-Anti-Backlash
Plate Installed on
Countershaft Gear
(3)
A-903:
Lubricate the bearing rollers with heavy
grease and install 22 rollers in each end of the gear
in the area around the arbor. Coat with heavy grease
and install the bearing spacer rings in each end of the
gear.
A-745:
Lubricate the bearing rollers with heavy
grease and install 22 rollers next to spacer in each
end of the gear in the area around the arbor. Place a
bearing spacer ring in each end of the gear next to
the bearing rollers and install another row of
22
roll-
ers in each end. Coat with heavy grease and install the
bearing spacer in each end of the gear.
(4) If
countershaft gear end play was found to ex-
ceed .028 inch during disassembly, install new thrust
washers.
A-903:
Coat with heavy grease and install thrust
washer at each end of the countershaft gear and over
the arbor. Install the gear and arbor in the case mak-
ing sure the tabs on the thrust washers slide into the
grooves in the case.
A-745:
Coat with heavy grease and install front
thrust washer over the arbor at the front
of the
coun-
tershaft gear, with the tabs outward. Install the tabbed
rear thrust washer over the arbor with the tabs posi-
tioned in the grooves in the gear.
Install the remaining rear thrust washer plate over
the arbor at the rear of the gear. The washer plate
must be installed
so
the step on the plate will engage
on ledge inside rear of the case, thus preventing plate
rotation. Install the gear and arbor in the case making
sure the front thrust washer tabs slide into the
grooves in the case, and the rear
thrust
washer step
engages on the ledge.
(5)
Using the countershaft and a soft hammer, drive
the arbor forward out of the countershaft gear and
through the bore in the front of the case. Before driv-
ing countershaft all the way into case, be sure keyway
is positioned in line with key recess in rear of case.
Insert shaft key and continue to drive countershaft
forward in case until key is bottomed in recess.
Reverse Idler Gear
(1) Position arbor Tool C-464 in the reverse idler
gear and using heavy grease, install 22 roller bear-
ings in the gear.
(2)
Place the front and rear thrust washers at each
end of the reverse idler gear, and position the assem-
bly in the transmission case with the chamfered end
of the gear teeth toward the front.
(3) Insert the reverse idler shaft into the bore at
rear of case with keyway to rear, pushing the arbor
toward the front of the transmission.
(4)
With keyway aligned with recess in case, drive
the shaft forward, inserting key before the keyway
is obscured. Continue driving shaft forward until key
seats in recess.
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