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2 1-26
1RANSMlSSlON-A-SPEED MANUAL
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1
C-3938
ARBOR
64
x
753A
Fig. 5 L R e m o v i n g or Installing Countershaft
Gear and Arbor
oil seal.
(3) Using a pair of snap ring pliers, remove the
main drive pinion bearing outer snap ring, using a
plastic hammer, drive the main drive pinion into the
case and remove.
(4)
Using snap ring pliers, remove the main drive
pinion bearing inner snap ring. Using an arbor press,
remove the bearing from the main drive pinion.
( 5 )
Remove the snap ring and 16 bearing rollers
from the cavity in the drive pinion.
(6) Remove the countershaft gear (cluster) from the
bottom of the case (Fig. 54).
(7) Remove the arbor and the 76 needle type bear-
ings, thrust washers and spacer, from the center of
the countershaft gear.
CLEANING AND INSPECTION
Clean the transmission case thoroughly, using a
suitable solvent, dry with compressed air. Inspect the
case for cracks, stripped threads in the various bolt
holes and the machined mating surfaces for burrs,
nicks or any condition that would render the case un-
fit for further service. The front mating surface
should be smooth; if any burrs are present, dress
them off with a fine mill file. If threads are stripped,
install Helicoil inserts.
Ball
Bearings
blow dry with compressed air.
Wash the ball bearings, using a clean solvent and
CAUTION: Do not spin the bearings with air pres-
sure; turn slowly by hand. Spinning unlubricated
bearings may cause damage to the races and the
balls.
Be sure the ball bearings are clean, then lubricate
them with light grade engine oil. Inspect the bearings
for roughness. This can best be determined by slowly
turning the outer race by hand. Measure the
fit
of the
bearings on their respective shafts.
Needle Type Bearing Rollers and Spacers
Inspect all bearing rollers for flat spots or brinel-
ling. Inspect all bearing roller spacers for signs of
wear or galling. Install new parts as required.
Gears
Inspect the gear teeth on the synchronizer clutch
gears and stop rings. If there is evidence of chipping
or excessively worn teeth, install new parts at reas-
sembly. Be sure the clutch sleeve slides easily on the
clutch gear. Inspect the countershaft gear and all slid-
ing gear teeth for chipped or broken teeth,
or
show-
ing signs of excessive wear. Small nicks or burrs must
be stoned off.
Inspect the teeth on the main drive pinion. If ex-
cessively worn, broken or chipped, a new pinion
should be installed.
Test the interlock sleeve and pin for free move-
ment in the bore of the shift housing. Examine the
detent balls for signs of brinelling. If the lever de-
tent show signs of excessive wear to the extent of 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.
M
a i m
h
af t
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 and Drive Pinion
(1)
Using heavy grease, coat the inside of the bore
of the gear at each end, then install the roller bearing
spacer; centered. Insert arbor Tool C-3938, into the
gear and through the spacer. Center the arbor.
(2)
Coat the needle type roller bearings with heavy
grease, then at each end of the gear, install 19 rollers,
followed by a spacer ring and 19 more roller bearings
and
1
spacer ring (Fig.
40).
(3) If the countershaft gear end play exceeded
.028"
when measured during disassembly of "Exten-
sion Housing and Mainshaft," Step 11, install new
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