Output Shaft Repair

NOTE: Transfer shaft should be removed for repair of output shaft. Planetary gear sets must be removed to accurately check output shaft bearing turning torque.

STIRRUP AND RETAINING STRAP

Fig. 161:

NOTE: A stirrup and retaining strap (Fig. 161) is attached to the output gear. The stirrup prevents the output gear retaining nut from turning and backing off the output shaft. The strap is used to hold the stirrup to the output gear and prevent the stirrup retaining bolts from backing out.

REMOVAL

Fig. 162:

1. Using a punch, bend tabs on strap flat against output gear (Fig. 162).

Fig. 163:

2. Remove bolts holding retaining strap to stirrup (Fig. 163).

Fig. 164:

3. Remove strap from output gear and stirrup (Fig. 164).

Fig. 165:

Fig. 166:

4. Remove stirrup from output gear (Fig. 165) (Fig. 166).


OUTPUT GEAR AND SHAFT
DISASSEMBLY

Fig. 167:

Fig. 168:

Fig. 169:

Fig. 170:

Fig. 171:

Fig. 172:

Fig. 173:

Fig. 174:

Fig. 175:

ASSEMBLY

Fig. 176:

Fig. 177:

Fig. 178:

Fig. 179:

Fig. 180:

DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of the following parts are replaced:
- Transaxle case
- Output shaft
- Rear planetary annulus gear
- Output shaft gear
- Rear annulus and output shaft gear bearing cones
- Overrunning clutch race cups

Fig. 181:

Fig. 182:

Fig. 183:

Fig. 184:

Fig. 185:

Fig. 186:

Fig. 187:

Refer to Adjustments for procedure to determine proper shim thickness. Check output shaft bearing turning torque, using an inch-pound torque wrench. If turning torque is 3 to 8 inch-pounds, the proper shim has been installed.

STIRRUP AND RETAINING STRAP
INSTALLATION
Once bearing turning torque and shim selection has been adjusted, install stirrup and strap assembly onto output gear.

NOTE: Once the stirrup assembly is positioned onto the output gear, it is necessary to "clock" the stirrup against the flats of the output gear retaining nut.

1. Position the stirrup on the output gear.
2. Position strap.
3. Install retaining bolts into output gear. Finger tighten bolts.

Fig. 188:

4. Turn stirrup clockwise against the flats of the output gear retaining nut (Fig. 188).

Fig. 189:

5. Tighten retaining bolts to 23 Nm (200 in. lbs.) (Fig. 189).
6. Bend tabs of strap up against "flats" of retaining bolts.