Countershaft and Reverse Idler Gear Installation

1. Install front bearing on countershaft with Installer Tool C-4340, or equivalent.
2. Lubricate countershaft front bearing cup and cone with petroleum jelly.





3. Position gear case on end with rear of case facing up.
4. Install countershaft in gear case. Do not install rear countershaft bearing on countershaft at this time.





5. Lubricate reverse idler gear bearings with petroleum jelly and install first bearing and second bearing.
6. Install idler gear front thrust washer on boss in gear case. Coat thrust washer with liberal quantity of petroleum jelly to hold it in place.





7. Install reverse idler gear in case.
8. Install idler gear rear thrust washer between idler gear and case boss.
9. Align idler gear bearings and thrust washers with drift.





10. Install reverse idler shaft. Be sure notched end of shaft is facing countershaft as shown.





11. Lift countershaft upward and position wood block between front of shaft and case.





12. Install rear bearing cone on countershaft with Installer Tool C-4040, or equivalent.
13. Remove wood block from under countershaft and lower countershaft front bearing into front bearing cup.
14. Lubricate countershaft rear bearing cup and cone with petroleum jelly.





15. Install countershaft rear bearing cup in gear case and over rear bearing. Tap cup into place with plastic mallet if necessary.





16. Install countershaft rear bearing plate. Be sure plate is seated in notch in reverse idler shaft before tightening bearing plate bolts.





17. Apply MOPAR silicone adhesive/sealer to flange and lip of new cap. Install new front bearing cap in gear case with Handle C-4171 and Installer C-3972-A, or equivalents.