D. Countershaft Extension Assembly

^ Tools Required:
- J 5590 Press Tube
- J 22910-01 Split Plate
- J 39442 Press Adapter
- J 39443 Split Plate
- J 39473 Bearing Installer
- Hydraulic Press
- V-Blocks

DISASSEMBLE
1. 5th/6th shift fork (122).
2. Thrust Washer (108).
3. 6th drive gear (109).
4. Caged needle bearing (110).
5. Spacer (115).
6. 6th drive gear blocker ring (114).
7. 5th/6th synchronizer snap ring (116) and discard.
8. 5th drive gear (126) using J 22910-01 and hydraulic press.
- 5th/6th synchronizer assembly (117) and 5th drive gear blocker ring (125) will press off with 5th drive gear (126).
9. 5th drive gear caged needle bearing (127).

Important
- Do not replace small tapered bearing (129) unless inspection shows bearing damage.

10. Small tapered bearing (129) using J 39442, J 39443 and hydraulic press.

Clean
- Countershaft extension components with solvent and dry with compressed air.

Inspect
Countershaft extension components.
- Shaft (128) and spline for excessive wear or cracks. Replace if these conditions exist.
- Gear teeth (109 and 126) for excessive wear, pitting, scoring, spelling or fractures.
- Bearing (129) for roughness of rotation, burred or pitted conditions. Replace if these conditions exist.
- Synchronizer (117). Refer to "Synchronizers" in this section.

NOTICE: When replacing bearing (129) also replace bearing race (130).

NOTICE: If scuffed, nicked, burred or scoring conditions cannot be reconditioned by hand with a soft stone or crocus cloth, replace the component.

ASSEMBLE
1. New small tapered bearing (129) using J 39473, V-blocks and hydraulic press.
2. 5th drive gear caged needle bearing (127).
3. 5th drive gear (126).
4. 5th drive gear blocker ring (125).

Important
- When pressing the 5th/6th synchronizer assembly (117).

A. Start press operation. "STOP" before keys engage blocker ring slots.
B. Lift and rotate 5th drive gear (126) to engage keys with blocker ring.
C. Continue to press until seated.
5. 5th/6th synchronizer assembly (117) using J 5590 and hydraulic press.
- Install 5th/6th synchronizer so ID groove on sleeve faces 5th gear.
6. New 5th/6th synchronizer snap ring (116).
7. 6th drive gear blocker ring (114).
8. 6th drive gear spacer (115).
9. 6th drive gear caged needle bearing (110).
10. 6th drive gear (109).
11. 6th drive gear thrust washer (108).
12. 5th/6th shift fork (122).