12. Output Shaft Clearance Measurement

1. Remove output shaft bearing from case. (Refer to "Bearing Removal" procedure.)
2. Install output shaft bearing on shaft.
3. Install 1st driven gear and sprag clutch assembly.
4. Install 1st driven gear thrust washer.

IMPORTANT: To aid in holding output shaft, install shaft into converter housing and engage park pawl.

5. Assemble output shaft. Use old nut and torque.
- Torque: 150 Nm (111 ft. lbs.)





6. Measure clearance between 4th driven gear and 3/4 thrust bearing. Make sure it spins and check maximum clearance.
Clearance:
Maximum: 0.464 mm (0.018 inch)
Minimum: The gear must rotate freely on the shaft.





7. Measure clearance between 2nd driven gear and the dog clutch hub.

IMPORTANT: Move dog clutch sleeve as necessary to gain access for measurements.

Clearance:
Standard: 0.050 mm - 0.150 mm (.002 inch - .006 inch)





8. Measure clearance between reverse driven gear and reverse driven gear thrust washer.
Clearance:
Standard: 0.066 mm - 0.172 mm (0.003 inch - 0.007 inch)
Minimum: The gear must rotate freely on the shaft.





9. Measure clearance between 1st driven gear washer and 1st driven gear.
Clearance:
Standard: 0.100 mm - 0.400 mm (0.004 inch - 0.016 inch)





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

NOTICE: Input shaft, output shaft, and differential must be installed at same time or damage will result to output shaft roller bearing inner race. Bearing failure will result.

IMPORTANT: If the stator shaft needle bearing assembly and input shaft to converter O-ring were not installed during input shaft assembly, make sure to lubricate and install the stator shaft needle bearing assembly on the input shaft or in the stator shaft prior to installing the shafts into the converter housing.





11. Install input shaft, output shaft, and differential. Grasp input and output shafts and mesh gears. Have assistant mesh differential ring gear to output shaft. Lower three components at same time. Apply petroleum jelly on output shaft bearing to aid in installation.