Continuing on with the build..... we now gather together the countershaft components, 2300-42 countershaft, 2303-41 cluster gear, the two 2305-39 right roller bearing end washers, 2305-33 left inner thrust washer, and the 2308-33 left outer thrust washer. Next step is to choose the size roller sets we will be using. Mic and record the countershaft roller bearing journals. Mic and record the roller bearing races on both ends of the countershaft. Do the same math for a .0006" to .0008" clearance calculation. Choose the correct size 2306-32 left side rollers and also the 2289-39 right side rollers.
This being accomplished, we will now assemble the rollers, countershaft, cluster gear, and thrust washers together. I lightly grease both cluster gear bearing races, the counter shaft roller bearing journals, and both faces of each thrust washer. Next I position the 2305-33 left inner thrust washer and the one 2305-39 right inner thrust washer, into their respective positions, inside the cluster gear roller bearing race journal, up against the bearing race shoulders. I then place the 2308-33 left outer thrust washer onto the countershaft, sliding it all the way back to the splined journal shoulder. Next... using tweezers, I now insert the correct rollers into both ends of the cluster gear. This procedure can be a little tricky. Take your time doing this because the least little jarring can cause the rollers to fall back out of their positions. Now I insert the countershaft into the cluster gear. Gentle handling is needed here also. I hold the cluster gear in a vertical position, small end facing downward. I then align the countershaft to the large end bearing rollers and carefully slip the countershaft through the first set of roller bearings, and continue sliding the countershaft on through the next set of roller bearing at the other end of the cluster gear. I then install the 2305-39 right outer roller thrust washer. Next , I set the assembly off to the side with components 2165-32 starter clutch gear, 2166-26 starter clutch spring, and the 2168-26 countershaft spring.
Preparing gearbox for countershaft installation...... The next step is to install the 2165-32 starter clutch gear and the 2166-26 starter clutch spring into the gearbox. Looking into the splined bore of the starter clutch gear, you will see there is one wide spline. I use this wide spline as an installation reference, by installing the starter clutch gear, with the wide spline facing up, in a vertical positon, once the starter clutch gear has been installed into the gearbox. Both the starter clutch gear and the starter clutch spring, are installed into the gearbox, at the same time. The starter clutch gear has two radius shaped legs on the one side, which engage in under the two 2172-26 tripper bolts. The starter clutch gear also has a pilot flange for the 2166-26 starter clutch spring to align to. The left side 2312-26 countershaft gearbox bushing, also has a pilot flange for the starter clutch spring to align to. Grasping the starter clutch gear in your hand, radius legs of the starter clutch gear facing away from your hand, install the starter clutch spring onto the starter clutch gear. Position the starter clutch gear in your hand with the wide spline of the starter clutch gear bore, vertical and at the top. Twist you hand counter clockwise, so that the radius legs of the starter clutch gear will miss the tripper bolt heads. Place the starter clutch gear and starter clutch spring into position, over the left case countershaft bushing. Compress the spring until the radius legs of the starter clutch gear make contact with the face of the left gearbox countershaft bushing. Now rotate the starter clutch gear clockwise, until the radius legs of the starter clutch gear slip in under the tripper bolt heads. Adjust splined bore of the starter clutch gear until the major diameter of the splined bore is in alignment with the left gearbox countershaft bushing, and....the wide spline is facing up, in a vertical position.
Now we can install the countershaft assembly...... Install the 2168-26 countershaft spring into the small bore on the left end of the countershaft.
Hold the countershaft assembly in you hand, so as not to allow the cluster gear to lose position against the shoulder on the countershaft. Position the wide spline of the countershaft as you positioned the wide spline of the starter clutch gear. Install the countershaft assembly into the starter clutch gear and left side countershaft bushing. This is a bit tricky also. The countershaft assembly will not enter the gearbox where the countershaft position is. You must start the entry near the mainshaft area first. Once the large diameter gear of the cluster gear, makes entry, you can shift the assembly, back into it's respective gearbox location, and continue installing it. Gently align the countershaft splined diameter to the starter clutch splined bore. This is why we positioned the wide splines where we did. It greatly helps in the installation of the countershaft assembly. Now....being extra careful while installing the countershaft assembly, completely through the starter clutch gear, and into the left gearbox countershaft bushing, Complete the countershaft assembly installation. DO NOT TURN THE COUNTERSHAFT !!!!!!
Doing so, will disengage the starter clutch gear from the tripper bolt heads !!! You will then have to start all over again.
You will notice the large gear teeth of the cluster gear do not fully mesh and engage with the clutch gear teeth. This is because the countershaft spring is preventing full engagement. Not to be concerned with though. Once the side cover is on, the countershaft spring will compress and the two will mesh together then.
We can now install the mainshaft assembly......
Place the 2298-41B low gear shifter clutch and the 2298-41 second and high gear shifter clutch into their respective positions, on the mainshaft assembly. Align the mainshaft assembly to the gearbox and carefully install it into the clutch gear, making sure the two shifter clutches are not engaged into the gears. You will need the two gears to move freely, so you can mesh gear teeth, to each other, as you fully install the assembly into the clutch gear. Both countershaft and mainshaft assemblies are installed into the gearbox. Now install the 2262-39 countershaft side cover seal washer onto the countershaft. Grease the washer all over.
Now we can install the gasket, side cover, mainshaft roller bearings, and 2291-33 right outer roller mainshaft thrust washer.
We will be using the previous procedures for installing the side cover but you will find it a bit more taxing as you install it, due to the resistance caused by the 2168-26 countershaft spring and the 2262-36 countershaft side cover seal washer. If you gradually tighten all fastens down, using a staggering sequence, buttoning up the side cover, will go smoothly.
Once you have the side cover completely tightened down, make sure the mainshaft , clutch gear, and cluster gear rotate ok. You will have slide the shifter clutches around , in order to check for free motion. The clutch gear will drag on the clutch gear oil seal some. Don't be concerned with that drag. Check for free movement of the countershaft. Using a wrench, on the squared end of the countershaft, turn countershaft counterclockwise, 180 degrees, until the slot cut into the square end of the countershaft is facing directly up in a vertical position. The starter clutch gear will disengage from the tripper bolt heads, engage into the cluster gear, and then re engage under the tripper bolt heads. The now present position of the countershaft, is where it will be, when the 2084-41 kicker spring and 2076-41A starter crank and pedal assembly, will be located, when transmission build is completed. Some resistance will be felt while you rotate the countershaft but to much is not good. Resistance must be less than the kicker spring strength is, or the countershaft will not return to it's correct position after kicking the transmission over, once final transmission build is completed, and all parts have been assembled.