How bad are these h55f layshaft gear chips to be considered replacing?

[Trubo Dislel]

I am rebuilding a 400kms h55f vacuum shift for a 12HT with a typical rebuild kit. First time doing such things however I did it in the wrong sequential however, tried removing the top shaft without popping the layshaft down first. In doing so I chipped around 5 or 6 layshaft teeth as shown in pictures.

Now these chips don't seem too life threatening, just in the corner of the ends. I have used a dremel to smoothen out the flesh of the chips and popped it back in. However totally related this is, I have lost many sleeping hours haunted by these chips in the layshaft, always getting nightmares about how these chips could get worse when driven. Done my fair share of research but could not find anything specific. What do you guys think? Should I call it a day and close it in with the bearings or pop it out and replace the entire layshaft considering how the chips look? Also considering the wear on bearing surfaces and the counter 5th gear synchro assembly teeth as attached, that is also very terribly worn. I have also dremelled it and lost sleep to it as well.

I've made the mistake of installing the toughest bearing on the output shaft before I got some insight on this issue, also don't want to spend a nice chunk on a new layshaft if it can run another 400kms looking like that. If you guys have some Ideas that would be great!

(The dent on top of that teeth is orginally there)

 

[Eurasiaoverland]

It would have been a good idea to download a free factory service manual for the transmission or the vehicle as a whole and avoided these simple mistakes.

I can't see the chipped gear teeth making much difference. How are the index teeth on the input shaft?

The splines for the counter fifth synchro hub look a bit chewed, but if the hub goes on tightly with no play, they are fine.

How is the rear bearing surface on the layshaft? That often wears.

 

[rick_d]

I'd say its farked and need to replace the countershaft. Georg E what are your thoughts?

 

[Trubo Dislel]

It would have been a good idea to download a free factory service manual for the transmission or the vehicle as a whole and avoided these simple mistakes.

I can't see the chipped gear teeth making much difference. How are the index teeth on the input shaft?

The splines for the counter fifth synchro hub look a bit chewed, but if the hub goes on tightly with no play, they are fine.

How is the rear bearing surface on the layshaft? That often wears.

I've got a brand new replacement for the input shaft since the end that goes into the spigot bearing is terribly worn out.

The layshaft bearing surfaces does see wear to it, have not got a micrometer to measure to factory specs but this is what they look like.

Tell me if the whole thing needs replacing or not. I am willing to do it just need to remove the untimely installed output shaft bearing.

 

[Eurasiaoverland]

Looks like there is pitting on the rear layshaf bearing surface, in which case I would say it needs to be replaced.

 

[Trubo Dislel]

Thanks for your help. Replace it is