Output Shaft

Disassemble




1. Remove reverse driven gear washer.

2. Remove reverse driven gear.

3. Remove reverse driven gear bearing.

4. Position press support below 2nd/ reverse driven gear thrust washer, then press off the following components:

a. Reverse driven gear bearing race.

b. Forward/reverse dog clutch sleeve.

c. Forward/reverse dog clutch hub.

d. 2nd/reverse driven gear.

e. 2nd/reverse driven gear bearing, if equipped.

f. 2nd/reverse driven gear bearing race.

g. 2nd/reverse driven gear thrust washer.

5. Remove 2nd/3rd driven gear spacer.

6. Using suitable gear puller, remove 3rd driven gear.

7. Remove 3rd driven gear split thrust washer.

8. Remove 3rd/4th gear thrust bearing.

9. Remove 4th gear and hub assembly.

10. Remove 4th driven gear bearing.

11. Remove 4th driven gear thrust bearing.

12. Remove 4th driven gear thrust washer.

13. Remove 4th clutch assembly.

14. Remove two output shaft to 4th clutch hub O-ring seals on output shafts.


Assemble

1. Lube and install two output shaft to 4th clutch hub O-ring seals on output shaft.

2. Lube clutch housing I.D., then install 4th clutch assembly.

3. Install 4th driven gear thrust washer.

4. Lube and install 4th driven gear thrust washer bearing.

5. Install 4th driven gear bearing, then lube bearing.

6. Install 4th gear and hub assembly, rotate gear to align hub tangs with clutch plates.

7. Lube and install 3rd/4th gear thrust bearing.

8. Install 3rd driven gear thrust washer.

9. Install 3rd driven gear.

10. Install 2nd/3rd driven gear spacer.

11. Install 2nd driven gear thrust washer.

12. Using suitable heat gun, heat 2nd driven gear bearing race, then install.

13. Lube and install 2nd driven gear bearing.

14. Install 2nd driven gear.

15. Install forward/reverse dog clutch hub with wide end of slots toward 2nd gear.

16. Install forward/reverse dog clutch sleeve with sleeve outside groove toward reverse gear.

17. Using suitable heat gun, heat reverse driven gear bearing race, then install.

18. Lube and install reverse driven gear bearing.

19. Install reverse driven gear.

20. Install reverse driven gear thrust washer.



Inspection

1. Remove output shaft bearing to case.

2. Install shaft bearing to shaft.

3. Install reverse driven gear thrust washer.

4. Install 1st driven gear and spray clutch assembly.

5. Assemble output shaft and tighten old nut to specifications.




6. Measure clearance between 3rd driven gear and 3/4 drive gear thrust bearing; 0.007-0.018 inch clearance should be indicated.




7. Measure clearance between 2nd driven gear and dog clutch hub; 0.002-0.006 inch clearance should be indicated.




8. Measure clearance between reverse driven gear and reverse driven gear thrust bearing; 0.003-0.007 inch clearance should be indicated.




9. Measure clearance between 1st driven gear washer and 1st driven gear; 0.012-0.024 inch clearance should be indicated.

10. Remove output shaft attaching nut, 1st driven gear thrust washer, 1st driven gear, sprag assembly and output shaft bearing.

11. Install input, output shafts and differential, hold input and output shafts and mesh gears, mesh differential ring gear and output shaft, lower three components to case. Input shaft, output shaft and differential must be in stalled at the same time or damage may result to output shaft roller bearing inner race.