Any thoughts on how to press the 5th and 6th back on the countershaft? I am thinking of heating the gear in a heat box and cooling the shaft with dry ice. I can only find a 25 ton press and that was barely enough to get them apart. I'm all ears to any ideas......

 

read post on other forum, the answer was given on Cummins Forum. Or perhaps you didn't believe and wanted a easier answer.

 

Calm down dozer.....I am a member on 3 sites and posted the same question on all 3 at the same time. (Or within minutes of each other.) I am on this one, Cumminsforum (for about 5 hours now...) and the TDR.

Never the less, the 6th gear went right on without any hassle. 5th is obviously tighter and I'll wait till monday for that. 6th was WAAY tighter as they came off. Maybe that's because I replaced the 6th with another gear after I chipped teeth getting it off. (The gears teeth....not mine)

 

O'K. On the chipped teeth. If you only chipped 1/8 inch or so on them, you could dress edges of chips and use them. A carefull inspection of teeth will show very little pressure exerted on edge of teeth since there is every so small amount of crown built in. Remember get the gear really hot and don't make mistake on install. I once tried a 100 ton press to get gear on. When if finally moved on (quite suddenlly) the press jumped two inches and scared the sxxx out of me. That is when decided factory manual was incorrect.
How do I know? Was at first class Chrysler taught in field.

 

Appreciate the advice on gear teeth. I probably would have been ok, but for the hell I had getting it off in the first place I didn't want to take any chances. Same reason why I replaced some of the bearings. They might have been ok, but I hope I never have to open this thing back up again!

 

- Here you can see the springs, dogs, and ball bearing inserts that go under the shift fork. I have easily spent 4 hours trying to install 6 of them. (I am getting alot better at it though!)
- Then you can see the 3 and 4th gears and synchro assembly lookin all pretty there.
- I then placed the countershaft next to the main shaft. (the 5th and 5th countershaft gears are missing)
- finally, you can see my nice duct tape job holding the 3 and 4 synchro together as I hold the 5th and 6th countershaft gears in place and you can see it all together minus the reverse assembly which goes in the the tail shaft.

I have the 6th C.S. gear pressed on now and am going to heat the 5th C.S. gear and try to press it on maybe today. It's been a long time but I can finally see the light at the end of the tunnel!

 

forgot the last one.....

 

Well, she's back together! (except for the tail housing and reverse gear) I was checking for end play as per specs and got about.004"-.005" with no shims. I took no shims out when it came apart.....does this sound right? I did notice that with the gauge set at .000" I get almost .015", but when I let off the pry bar it only comes back about half way. What is going on?
I really hope one of ya'll can help me as I would LOVE to have this done before Blumenthal's opens on Monday!

I'll post a few pics later tonight or in the am.