REPAIR INSTRUCTIONS 19. Remove the temporarily installed No. 1 and No. 3 front countershaft rear bearing cover capscrews, covers and spacers.
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20. Using a brass hammer, tap the No. 1 and No. 3 reverse idler shafts until fully seated in the case. 524
Figure 522 — Installing Mainshaft into Case
16. Place the transmission in a horizontal position. 17. Move the reverse gear and Lo/reverse sliding clutch to normal positions. 18. Position the mainshaft, No. 3 (lower) countershaft and No. 1 (upper right, when viewed from the front) countershaft so that the timing marks on the gears are aligned. Roll the shafts into place and make sure gear timing is correct.
Timing the shafts is easier if the transmission is in a horizontal position, rotated 15 degrees counterclockwise, as viewed from the rear of the transmission case. 523
Figure 524 — Tapping Reverse Idler Shaft into Place
21. Temporarily reinstall the No. 1 and No. 3 front countershaft rear bearing covers (without 1/2-inch thick spacers) to secure the countershafts. Jiggle the countershafts while tapping the covers in place. Install the capscrews, but do not tighten to specification at this time. Front countershaft bearing preload must be adjusted after main case assembly.
Do not use the bearing cover capscrews to pull any bearing cover into place. Damage to the bearings or bearing cover may result. Make sure all components are properly in place before tightening the capscrews.
Figure 523 — Timing Gears with Mainshaft in Place
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22. Install the remaining No. 2 reverse idler shaft, gear and thrust washer (next to No. 2 countershaft, not yet installed) as described in the steps for the lower (No. 3) reverse idler shaft and gear. Move the reverse speed gear on the mainshaft as far away as possible. When installing the reverse idler shaft and gear, make sure that the thrust washer is held in place.
