49. Output Shaft Assemble

Output Shaft Assemble

- Tools Required
- DT 46509 Tube Style Driver, 40 mm LD





1. Install the 2nd driven gear (523) on the output shaft (524).
2. Install the 2nd driven gear 65 mm x 83 mm x 4.5 mm thrust bearing (522) on the output shaft (524).
3. Install the 1st and 2nd idler gear 57 mm x 65 mm x 28.7 mm inner bearing (521) on the output shaft (524).
4. Install the 1st and 2nd idler gear (520) on the output shaft (524) as shown in insert.
5. Install the 2nd idler gear 56 mm x 87.5 mm x 5.5 mm thrust bearing (519) on the output shaft (524).
6. Install the 1st driven gear 56 mm selective spacer (518) on the output shaft (524)
7. Install the 1st driven gear (517) on the output shaft (524) as shown in insert.
8. Install the 3rd and 4th driven gear (500) on the output shaft (524) as shown in insert.
9. Install the 3rd and 4th driven gear 52 mm selective spacer (501) on the output shaft (524)
10. Install the 3rd and 4th driven gear 39 mm split retaining ring (502) on the output shaft (524).
11. Install the 3rd and 4th driven gear 39 mm split retaining ring cap (503) on the output shaft (524).
12. Install the 3rd and 4th driven gear 39 mm split retaining ring cap retainer (504) on the output shaft (524).
13. Install the 5th driven gear 35 mm x 47 mm x 6 mm spacer (505) in the direction shown in the insert.
14. Install the 5th driven gear 35 mm x 21 mm x 46 mm inner bearing (506).
15. Install the 5th driven gear (507).





16. Using the DT 46509 and a hydraulic press, slide the 5th and reverse synchronizer hub (509) over the output shaft (524), and then press it into place.

Note: Some reverse selector hubs do not require a press to be installed.





17. Install the 5th and reverse synchronizer ring (508) on the output shaft assembly (524).
18. Install the reverse driven gear 31 mm x 40 mm x 14.5 mm inner bearing race (510) on the output shaft assembly (524).
19. Install the reverse driven gear 40 mm x 46 mm x 14.5 mm inner bearing (511) on the output shaft assembly (524).
20. Install the reverse driven gear (512) on the output shaft assembly (524).





21. Using the DT 46509 and a hydraulic press, install the output shaft 31 mm x 93 mm x 19 mm rear case bearing (514) over the output shaft (524), and then press the bearing into place.





22. Install an output shaft conical spring washer (515) in the direction as shown, and then install an output shaft locknut (516). Do not use an impact wrench to install locknut.






Notice: Refer to Fastener Notice in Cautions and Notices.

23. Hold the output shaft (524) securely and tighten the locknut (516). Use a torque wrench to tighten locknut (516). The locknut is left-hand thread design.
- Tighten the locknut to 167 Nm (123 ft. lbs.).





24. Stake the output shaft locknut (516) in place on the output shaft (524) to the specified depth (a) using a 3.5 mm punch (b).
Specification:
- Stake the locknut to 0.7 mm-1.3 mm (0.03-0.05 inch)