Reverse Idler and Countershaft Removal

Removing Countershaft Rear Bearing Plate:

1. Remove countershaft rear bearing plate.

Countershaft End Play Shim And Rear Bearing Cup Removal:

2. Remove countershaft end play shim and rear bearing cup.

Removing Reverse Idler Shaft:

3. Remove reverse idler shaft.

Idler Gear Moved Away From Countershaft:

4. Rotate countershaft outward and push reverse idler gear away from countershaft and toward front of case.

Reverse Idler Gear Removal:

5. Remove idler gear.

Reverse Idler Gear Componenets:

6. Keep reverse idler gear bearings and spacer together for cleaning and inspection. Insert idler shaft through gear and bearings to keep them in place.
7. Remove idler gear thrust washers from gear case. Install washers on idler shaft to keep them together for cleaning and inspection.
8. Remove countershaft, rear bearing. Shaft cannot be removed from case until rear bearing has been removed. Bearing removal procedure is as follows:

Removing Countershaft Rear Bearing:

a. Assemble Puller Flange 6444-1 and Puller Rods 6444-4.
b. Position first Puller Jaw 6449 on bearing cone.
c. Seat puller flange in notch of puller jaw just installed on bearing cone.
d. Install second Puller Jaw 6449 on bearing and in notch of puller flange.
e. Slide Retaining Collar 6444-8 over puller jaws to hold them in place. Note that retaining collar has small lip on one end and only fits one way over jaws.
f. Install Puller 6444 on puller rods. Then secure puller to rods with retaining nuts.
g. Tighten puller bolt to remove bearing from shaft. If bearing is exceptionally tight, tap end of puller bolt with copper mallet to help loosen bearing.
9. Remove bearing puller tools.

Removing Countershaft From Gear Case:

10. Rotate countershaft out of gear case.
11. Remove countershaft front bearing as follows:

Removing Ountershaft Front Bearing:

a. Assemble Puller Flange 6444-1 and Puller Bolts 6444-4.
b. Position first Puller Jaw 6451 on bearing.
c. Seat puller flange in notch of puller jaw.
d. Install second Puller Jaw 6451 on bearing and in notch of puller flange.
e. Slide Retaining Collar 6444-8 over puller jaws to hold them in place. Note that retaining collar has small lip on one end and only fits one way over jaws.
f. Install Puller Bridge And Bolt Assembly 6444 on puller bolts. Then secure bridge to bolts with retaining nuts.
g. Tighten puller bolt to remove bearing from shaft. If bearing is exceptionally tight, tap end of puller bolt with mallet to help loosen bearing.
12. Remove bearing puller tools.
13. Set countershaft and idler gear aside for cleaning and inspection.