Assembly

ASSEMBLY




1. Lubricate sun gear (2) and planetary gears with transmission fluid during assembly. Use petroleum jelly to lubricate intermediate shaft bushing surfaces, thrust washers and thrust plates (3) and to hold these parts in place during assembly.
2. Install front snap-ring on sun gear (2) and install gear in driving shell. Then install thrust plate (3) over sun gear and against rear side of driving shell (1). Install rear snap-ring (4) to secure sun gear and thrust plate in driving shell. Note that the large ID chamfer on the sun gear goes forward.




3. Install rear annulus gear (1) on intermediate shaft (2).




4. Install thrust washer (2) to rear planetary annulus gear (1) using petroleum jelly. Be sure washer is seated against corner with the tabs completely in the locating holes.




5. Install rear planetary gear (2) in rear annulus gear (1). Be sure planetary carrier is seated against annulus gear.




6. Install tabbed thrust washer (2) on front face of rear planetary gear (1). 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.
8. Install sun gear (5) and driving shell (2) on intermediate shaft (1). Seat shell against rear planetary gear. Verify that thrust washer on planetary gear was not displaced during installation.




9. Install tabbed thrust washer (3) in driving shell (2), be sure washer tabs are seated in tab slots of driving shell. Use extra petroleum jelly to hold washer in place if desired.




10. Install tabbed thrust washer (1) on front planetary gear (2). Seat washer tabs in matching slots in face of gear carrier. Use extra petroleum jelly to hold washer in place if desired.
11. Install the torlon bushing onto the front planetary carrier hub.




12. Install front annulus gear (1) over and onto front planetary gear (2). Be sure gears are fully meshed and seated.




13. Install front planetary and annulus gear assembly (2). 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.




14. Place geartrain 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.
15. Install new planetary snap-ring (2) in groove at end of intermediate shaft.




16. Turn planetary geartrain over. Position wood block under front end of intermediate shaft and support geartrain on shaft. Be sure all geartrain parts have moved forward against planetary snap-ring. This is important for accurate end play check.
17. Check planetary geartrain end play with feeler gauge (3). Insert gauge between rear annulus gear (2) and shoulder on intermediate shaft (1) as shown. End play should be 0.15 to 1.22 mm (0.006 to 0.048 in.).
18. If end play is incorrect, install thinner/thicker planetary snap-ring as needed.