REPAIR INSTRUCTIONS 8. Tip the No. 1 (upper left, when viewed from the rear) front countershaft into position as described earlier for the No. 3 (lower) countershaft.
521
9. Install the reverse idler gear and thrust washer into the opening next to the No. 1 (upper left) front countershaft. Roll the idler gear and thrust washer into position. 10. Install the reverse idler shaft. Align the flat on the end of the shaft with the mark previously made along the edge of the shim pack. 11. While maintaining mark alignment, use a brass hammer to tap the reverse idler shaft into the case. To ease installation of the mainshaft, do not drive the reverse idler shaft all the way into the case at this time. Leave approximately 1/2 inch of the shaft protruding above the case as shown in Figure 520.
Make sure that the thrust washer is aligned correctly with the idler shaft while tapping the idler shaft into place. If not aligned, damage to the thrust washer may result. 12. After installing the No. 1 and No. 3 reverse idler gears and idler shafts, install the front countershaft rear bearings onto the No. 1 and No. 3 countershafts. 13. To hold the No. 1 and No. 3 countershafts in place, temporarily install the front countershaft rear bearing covers. Position 1/2-inch thick spacers (nuts) between the bearing covers and the transmission case to allow for the temporary protrusion of the reverse idler shafts.
Figure 521 — Bearing Covers Temporarily Installed with Spacers
14. With the No. 1 and No. 3 front countershafts temporarily in place, move both countershafts as far rearward as possible, against the rear bearing covers. This provides clearance for mainshaft installation and Lo-speed gear and reverse speed gear positioning. Also, position the reverse idler gears as far rearward as possible. 15. Install the mainshaft into the case by lifting the mainshaft into position and in gear contact with the No. 1 and No. 3 countershafts.
Before the mainshaft is installed, slide the Lo/reverse sliding clutch forward until it fully engages the Lo-speed gear. Slide the reverse speed gear forward until it fully engages the sliding clutch.
Reverse gear is not secured to the shaft and can fall off if not careful.
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