97 GTS Transmission : countershaft stuck

[cyruss]

Hi everyone,

My transmission "broke" on the highway, doing 5th and 6th full throttle acceleration.

I start to disasembled my gearbox and found one broken key of the 5/6 synchro.

As I continue to remove all the internal parts to make a full rebuilt (with upgraded parts), I cannot pull out the countershaft as explained on the service manual.

It is so hard to pull it's look like it is a one piece countershaft ! (like Corvette ??) and not 2 pieces.

But there is no reason that it is not a 2 piece ... so any idea of how I can pull it out or why it got stuck ?

Here are some pictures...

Thank a lot for your Help ...

back of the transmission :
back GB.jpg

What I found on the magnet : part of the key of 5/6 synchro
reste.jpg

Pull the countershaft as explained on the Viper SM
SM Viper.jpg

Part detail on the Tremec SM
SM Tremec.jpg

Countershaft close look
a sortir.jpg

Picture found on internet, this should come like this :


Just slide out of the other piece of the countershaft :

[DSA_RYan]

you have a 2-pc counter shaft. the one piece counter shafts do not have have a taper bearing, they use a non taper roller bearing that is clipped into the tail housing

[DSA_RYan]

you have to remove the snap ring holding the the 5-6 shift fork to the shift rail to pull the counter shaft extension out, i can see from your photos it is still on. you also have to remove that small collar on the shift rail that has a roll pin through it and slide it off. with it still on you are fighting the whole shift rail and forks. if you tak that snap ring off it will pull off just like your photo.

[DSA_RYan]

the next issue you will run into it that 5-6 cluster gear on the main shaft, you need a special puller to pull it with out damaging it. and the synchro hub puller helps alot too.

[cyruss]

Thanks DSA, but the snap ring is gone (not on the picture), I remove the fork shaft completly. look at my last picture before I gave up

20150719_011846.jpg

[cyruss]

the next issue you will run into it that 5-6 cluster gear on the main shaft, you need a special puller to pull it with out damaging it. and the synchro hub puller helps alot too.

That would be the next step indeed. I have a puller and I could buy a longer one if it is not enough.

[DSA_RYan]

with that shift fork gone, and the 5/6 cluster gear all ready off as in your latest picture it will pull right out. if it dosnt pull out whack it with a plastic mallet in the direction to pull the extension out of the counter shaft. more than likely something is wrong with either the counter shaft or the extension shaft that a force from the rear has pressed the extension too far into the counter shaft. alot of times the counter shaft with break a ear off then.

[cyruss]

Thanks for the info, I will try harder to whack it. Sadly I'm far from home for work so I would try in a couple of weeks only ....

As I wasn't sure I did not hammer it too much, but if you say it should go ... then I will pull !

Just for the sake of knowing, do you have an idea on how the countershaft could get that stuck ? too much torque ?

[cyruss]

in the direction to pull the extension out of the counter shaft.

The problem is that the access is not easy to whack it from behind to help him going out.