Planetary Gear-Train/Output Shaft

DISASSEMBLY

Removing Planetry Snap Ring:

1. Remove planetary snap ring from intermediate shaft. Discard snap ring as it is not reusable.

Removing Front Planetary And Annulus Gears:

2. Remove front planetary gear and front annulus gear as assembly.

Disassembling Front Planetary And Annulus Gears:

3. Remove front planetary gear and thrust washer from front annulus gear. Note thrust washer position for assembly reference.

Driving Shell Thrust Washer Removal:

4. Remove tabbed thrust washer from driving shell. Note washer position for assembly reference.

Sun Gear And Driving Shell Removal:

5. Remove sun gear and driving shell as assembly.

Rear Planetary Thrust Washer Removal:

6. Remove tabbed thrust washer from rear planetary gear. Note washer position on gear for assembly reference.

Rear Planetary And Annulus Gear Removal:

7. Remove rear planetary gear and rear annulus gear from intermediate shaft.

Rear Annulus Thrust Plate Removal:

8. Remove thrust plate from rear annulus gear.

ASSEMBLY
1. Lubricate sun gear and planetary gears with transmission fluid during assembly. Use petroleum jelly to lubricate intermediate shaft bushing surfaces, thrust washers and thrust plates and to hold these parts in place during assembly.

Sun Ger Installation:

2. Install front snap ring on sun gear and install gear in driving shell. Then install thrust plate over sun gear and against rear side of driving shell. Install rear snap ring to secure sun gear and thrust plate in driving shell.

Installing Rear Annulus Gear On Intermedate Shaft:

3. Install rear annulus gear on intermediate shaft.

Installing Rear Annulus Thrust Plate:

4. Install thrust plate in annulus gear. Be sure plate is seated on shaft splines and against gear.

Installing Rear Planetary Gear:

5. Install rear planetary gear in rear annulus gear. Be sure planetary carrier is seated against annulus gear.

Installing Rear Planetary Thrust Washer:

6. Install tabbed thrust washer on front face of rear planetary gear. Seat washer tabs in matching slots in face of gear carrier. Use extra petroleum jelly to hold washer in place if desired.
7. Lubricate sun gear bushings with petroleum jelly or transmission fluid.

Installing Sun Gear And Driving Shell:

8. Install sun gear and driving shell on intermediate shaft. Seat shell against rear planetary gear. Verify that thrust washer on planetary gear was not displaced during installation.

Installing Driving Shell Thrust Washer:

9. Install tabbed thrust washer in driving shell, be sure washer tabs are seated in tab slots of driving shell. Use extra petroleum jelly to hold washer in place if desired.

Installing Thrust Washer On Front Planetary Hear:

10. Install tabbed thrust washer on front planetary gear. Seat washer tabs in matching slots in face of gear carrier. Use extra petroleum jelly to hold washer in place if desired.

Assembling Front Panetary And Annulus Gears:

11. Install front annulus gear over and onto front planetary gear. Be sure gears are fully meshed and seated.

Installing Front Planetary And Annulus Gear Assembly:

12. Install front planetary and annulus gear assembly. Hold gears together and slide them onto shaft. Be sure planetary pinions are seated on sun gear and that planetary carrier is seated on intermediate shaft.
13. Place gear-train in upright position. Rotate gears to be sure all components are seated and properly assembled. Snap ring groove at forward end of intermediate shaft will be completely exposed when components are assembled correctly.

Installing Planetary Snap Ring:

14. Install new planetary snap ring in groove at end of intermediate shaft.
15. Turn planetary gear-train over. Position wood block under front end of intermediate shaft and support gear-train on shaft. Be sure all gear-train parts have moved forward against planetary snap ring. This is important for accurate end play check.

Shecking Planetary Geartrain End Play:

16. Check planetary gear-train end play with feeler gauge. Insert gauge between rear annulus gear and shoulder on intermediate shaft as shown. End play should be 0.15 to 1.22 mm (0.006 to 0.048 inch).
17. If end play is incorrect, install thinner/thicker planetary snap ring as needed.