Output Gear Bearing Adjustment

1. With output gear removed: install a 4.50 mm (0.177 inch) gauging shim on the rear carrier assembly hub, using grease to hold the shim in place.
2. Using Tool 6259, install output gear and bearing assembly. Torque to 271 Nm (200 ft. lbs.).
To measure bearing end play:
3. Attach Tool L-4432 to the gear.
4. Push and pull the gear while rotating back and forth to insure seating of the bearing rollers.

Fig. 308:

5. Using a dial indicator, mounted to the transaxle case, measure output gear end play (Fig. 308).
6. Refer to the output gear bearing shim chart for the required shim to obtain proper bearing setting.

Output Gear Bearing Shim Chart:

Output Gear Bearing Shim Chart

Fig. 309:

Fig. 310:

7. Use Tool 6259 to remove the retaining bolt and washer. To remove the output gear, use Tool L-4407A.
8. Remove the gauging shim and install the proper shim (Fig. 309). Use grease to hold the shim in place. Install the output gear and bearing assembly (Fig. 310).

CAUTION: Always use new retaining bolt, old retaining bolt may not be reused.

Fig. 311:

Fig. 312:

9. Install the new retaining bolt and washer (Fig. 311). Tighten to 271 Nm (200 ft. lbs.) (Fig. 312).

Fig. 313:

10. Using an inch-pound torque wrench, check the turning torque (Fig. 313). The torque should be between 3 and 8 inch-pounds.
If the turning torque is too high, install a 0.04 mm (0.0016 inch) thicker shim. If the turning torque is too low, install a 0.04 mm (0.0016 inch) thinner shim. Repeat until the proper turning torque is 3 to 8 inch pounds.

Fig. 314:

Fig. 315:

Fig. 316:

Fig. 317:

Fig. 318:

Fig. 319:

Fig. 320:

NOTE: Install output gear stirrup and strap bolts.

All transaxles utilize a stirrup and retaining strap that is attached to the output gear. The stirrup prevents the output gear retaining bolt from turning and backing out of the rear carrier. The strap is used to hold the stirrup to the output gear and prevent the stirrup retaining bolts from backing out.

Fig. 321:

Fig. 322:

Fig. 323:

Fig. 324:

Fig. 325:

Fig. 326:

NOTE: Screw Tool 5049-A onto transfer shaft. Install transfer shaft.