Gearcase
GearcaseReplacement of output shaft bearing race
To remove
1. Set up the gearcase in a hydraulic press.
2. Press out the bearing race with 87 91 311 Sleeve, driver shaft bearing.
To fit
1. Turn the case and mount the bearing race with a plastic hammer. Press in the new bearing race until it bottoms with 83 90 312 Drift, input shaft bearing race. Use 87 91 188 Support, for removing pinion shaft for support.
Replacement of input shaft bearing race
To remove
1. Remove the 4 screws from the seal retainer. Keep the seal retainer, screws and shims.
2. Press out the bearing race with 87 90 800 Drift, differential bearing seal and 87 92 236 Support, for fitting F35 speed gear for support.
To fit
1. Turn the gearcase and fit the bearing race in position using a plastic hammer.
2. Press down the bearing race with 87 92 202 Sleeve and 87 91 188 Support, for removing pinion shaft until the tool bottoms on the gearcase.
3. Fit the bearing carrier with a nominal shims package of 1.5 mm. Tighten the bearing race alternately with the bearing carrier screws.
Tightening torque 38 Nm (28 ft. lbs.)
Bushings for selector shafts in gearcase
To remove
1. Tap out the 3 bushings in the gearcase carefully using 87 91 238 Drift, selector rod bush.
To fit
Important: The reverse selector shaft has no bush in the gearcase.
1. Tap in the bushings carefully with 87 91 238 Drift, selector rod bush.
Sintered plug, bleeding
To remove
1. Tap out the sintered plug from the gearcase using a drift from the outside.
To fit
1. Carefully tap in a new sintered plug from the mating surface (the sintered plug is tapered).
Important: Use a hollow drift or piece of tube so that the surface of the sintered plug is not compressed (blocked). If the surface of the sintered plug is blocked, its air-porous properties are destroyed and the oil in the gearbox may be forced out.
Gear selector arms
To remove
1. Tap out the retention pins and remove the gear selector arms. Lubricate the needle bearings with grease to keep the needles in place.
2. Remove the shafts. Retain the plastic washers and sealing rings.
Important: Needle bearings contain loose needles. Do not mix needles from different bearings as they are matched to the bearing race concerned.
To fit
1. Fit the sealing rings and shafts with plastic washers and gear selector arms. Make sure the needle bearing rollers are located correctly in the bearing.
Note: The washer to the gear selector arm is on the outside of the gearcase and the washer to the position selector is on the inside of the gearcase.
2. Tap in the new retention pins.
Reversing-light switch
To remove
1. Remove the reversing light switch
To fit
1. Wash the reversing light switch and the gearcase threads with Cleaning agent, Loctite Super Clean 7063.
2. Fit the reversing light switch. Apply Thread locking adhesive, Loctite 577 to the threads.
Tightening torque 24 Nm (18 ft. lbs.)