Output Gear Bearing Adjustment

1. With output gear removed: install a 4.50 mm (0.177 inch) gauging shim on the-rear carrier assembly hub, using grease to hold the shim in place.
2. Using Tool 6259, or equivalent, install output gear and bearing assembly. Torque to 271 Nm (200 ft. lbs.). To measure bearing end play:
3. Attach Tool L-4432, or equivalent to the gear.
4. Push and pull the gear while rotating back and forth to insure seating of the bearing rollers.

Checking Output Gear Bearing End Play:

5. Using a dial indicator, mounted to the transaxle case, measure output gear end play.





6. Refer to the output gear bearing shim chart illustrated for the required shim to obtain proper bearing setting.
7. Use Tool 6259, or equivalent to remove the retaining bolt and washer. To remove the output gear, use Tool L- 4407, or equivalent.

Output Gear And (Select) Shim:

Install Output Gear:

8. Remove the gauging shim and install the proper shim. Use grease to hold the shim in place. Install the output gear and bearing assembly.

CAUTION: Always use new retaining bolt, old retaining bolt may not be reused.

Install Output Gear Bolt And Washer:

Tighten Output Gear To 271 Nm (200 ft. lbs.):

9. Install the new retaining bolt and washer. Tighten to 271 Nm (200 ft. lbs.).

Check Output Gear Bearings Turning Torque:

10. Using an inch-pound torque wrench, check the turning torque. The torque should be between 3 and 8 inch-pounds.

If the turning torque is too high, install a 0.04 mm (0.0016 inch) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 inch) thinner shim. Repeat until the proper turning torque is 3 to 8 inch pounds.

NOTE: Install output gear stirrup and strap bolts.

Output Gear Retaining Bolt Stirrup (Serration Side Out):

Stirrup Strap (Align Strap Holes With Tapped Gear Holes):

Install Strap Bolts:

Turn Stirrup Clockwise Against Flats Of Output Gear Retaining Bolt:

Tighten Stirrup Strap Bolts To 23 Nm (200 inch lbs.):

Bend Tabs On Strap Up Against Flats Of Bolts:

All transaxles utilize a stirrup and retaining strap that is attached to the output gear. The stirrup prevents the output gear retaining bolt from turning and backing out of the rear carrier. The strap is used to hold the stirrup to the output gear and prevent the stirrup retaining bolts from backing out.

NOTE: Screw Tool 5049-A onto transfer shaft. Install transfer shaft.