D353 INDUSTRIAL & MARINE ENGINES Caterpillar


Countershaft

Usage:

Remove Countershaft

start by:

a) remove clutch shaft.

b) remove idler shaft.

1. Remove bolt and lock (1) from spanner nut for countershaft.

2. Loosen countershaft spanner nut with tool (A).

3. Remove bolts (2).

4. Remove retainer (3) and shims (4).

5. Remove the drive flange (5).

6. Remove bearing retainer bolts (6).

7. Remove bearing retainer (7) and shims (8).

8. Pull the countershaft from the countershaft gear (9) using tool (B).

9. Remove spanner nut and remove countershaft (10).

10. Fasten a C-clamp and hoist to the countershaft gear and lift gear from case.

11. Remove gear pan mounting bolts (11).

12. Remove gear pan (12).

13. Remove countershaft roller bearing retaining ring (13).

14. Remove countershaft bearing (14) using tool (C).

Install Countershaft

1. Install countershaft bearing using tool (A).

2. Install countershaft roller bearing retaining ring (1).

3. Install gear pan (2).

4. Fasten a C-clamp and hoist to the countershaft gear (3) and install in case.

5. Install countershaft taper race (4).

6. Install countershaft (5).

7. Support shaft and install spacer (6) and spanner nut (7).

8. Install bearing race (8).

9. Install seals (9) in bearing retainer. The seal contact of the outer seal must point to the rear, and the seal contact of the inner seal must point forward.

10. Install retainer (10) without shims. Install the retainer to the housing with two fastening bolts 180 degrees apart. The bolts should be turned only finger tight. Measure gap between retainer and case with a thickness gauge. Remove retainer and add shims (11) equal to the measured gap. Reinstall retainer and shims. Tighten bolts (12) to 85 lb. ft. (115 N·m).

11. Install drive flange (13).

12. Install O-ring seal (14).

13. Measure the distance from the end of the countershaft to the inner lip surface of the drive flange using a depth gauge. Install shims (15) that equal .010 to .015 in. (0.25 to 0.38 mm) less than the distance measured, and install retainer plate (16).

14. Put oil on countershaft taper. Do not assemble dry. Put countershaft gear (17) on the shaft.

15. Tighten spanner nut with tool (B), by rotating countershaft and holding spanner nut, until countershaft gear moves at least .025 in. (0.64 mm) onto taper of countershaft.


TYPICAL EXAMPLE

16. Check countershaft end play with tool (C). End play must be between .003 and .008 in. (0.08 to 0.20 mm).

end by:

a) install clutch shaft.

b) install idler shaft.

Disassemble Countershaft

start by:

a) remove countershaft.

1. Remove roller bearing retaining ring (1).

2. Pull the roller bearing race off of the shaft using tool (A).

3. Pull taper roller bearings off of the shaft using tool (B).

Assemble Countershaft

1. Put bearings in 275°F (135°C) oil and install on countershaft.

2. Make bearing inner race HOT and install on end of countershaft. Install retaining ring.

end by:

a) install countershaft.

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