Just so happens that as soon as I finished my engine.....I spent an entire day teaching a young guy how to refurbish his tranny. His tranny was leaking like a sumbitch, and when I volunteered to show him how to reseal it, I discovered that he had major issues with his main drive gear bushing...so I showed him how to completely remove and gut his tranny a few weeks ago. The gears were in good shape, but it was time for new bearings and a new countershaft...so, after saving up his pennies he finally got all of the parts he needed and we were good to go. I took these pictures as it went back together, figuring they may be of some use to anybody that's never been in their tranny before:

Starting off with the bare cases...no beadblaster, but a little elbow grease and hot water got 'em clean, even if stained a little:

Turns out one of his bottom case studs was flopping around...so I impressed him by installing a helicoil. It was a little tricky because that specific boss in the case is angled on the inside surface, to provide clearance...so I had to cut down the insert "just right" to remain consistent with that inner surface. I coated the insert with some epoxy to keep it oil tight after it cured:

Main drive gear ready for new bushing:

My trusty little "Harbor Freight" press has paid for itself in more ways than I can count!! Notice the "special" tool I used to press in the bushing:

I happen to own a "like new" old orignal HD drive gear bushing ream...and yes, I did oil the heck outta' it before I actually reamed the bushing...this was just a nice pose for the picture:

Bushing and new seal installed:

Pressed new bearings into the countershaft gear cluster:

And pressed new bushings into the ends of the mainshaft:

Mainshaft assembly started with first/second MS gear, bearing cup, shiny new shielded ball bearing, lockwsher and nut...ready to slide into the case:

While sliding the mainshaft assembly into the cases, ya' have to slip on third MS gear along with a thrust washer and retaining clip...getting the clip over the splines and in place can be a little bit of a pain, but no big deal with a nice pointy thingy to help:

Mainshaft and drive gear installed:

Securing the retaining plate (those old "hammer" impacts do come in handy still!):

Getting ready to slide in the assembled countershaft gear cluster with it's new shaft and bearings...notice I have already "glued" the thrust washer into the case with a dab of lube...makes it a little easier to slide the countershaft in with the case upright:

Countershaft all installed...setting the lockwasher tab:

Looking good:

Shift forks installed and adjusted (yes, I know...the "top hats" are missing...I don't put those on until just before I set the lid on...don't want one to fall in while I'm busy dicking around with something else!!):

I LOVE "Hylomar"...the world's BEST gasket dressing!!

Lid going on:

Installing tranny mainseal with another "special" tool:

Looking even better!

One of the RARE areas I recommend a little bead of silicone...along the main drive gear splines before the sprocket gets set in place:

Sprocket goes on with the recess facing the tranny....FLAT SIDE OUT!

Impact helps here:

Don't forget the lockwasher tab!

Getting kicker parts ready:

First the spring:

Then the sliding ratchet gear:

Then the kicker gear (keyed to the shaft and secured with a nut/lockwasher):

I replaced his kicker cover bushings too...since these are not some super "critical" engine or internal engine part...I just use a quick ball hone to fit 'em to the shaft, nice and simple and works fine:

Kicker shaft installed with kicker gear in cover with new bushings and new seal:

New throwout bearing and thrust washers with oil slinger...ready to go:

Cover installed:

All done...new studs, new bearings, new bushings, new seals....all for less than $150 or so.

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