Output Shaft Repair

DISASSEMBLY

Remove Output Shaft Retaining Nut And Washer:

Remove Output Shaft Gear:

Output Shaft Gear And (Select) Shim:

Remove Output Shaft Gear Bearing Cone:

Remove Output Shaft And Rear Annulus Gear Assembly:

Remove Output Shaft:

Remove Rear Planetary Annulus Gear Bearing Cone:

Remove Output Shaft Gear Bearing Cup:

Remove Rear Planetary Annulus Gear Bearing Cup:

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

Stirrup And Retaining Strap Assembly:

NOTE: A stirrup and retaining strap 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.

Bend Strap Tabs Flat:

1. Using a punch, bend tabs on strap flat against output gear.

Remove Strap Bolts:

2. Remove bolts holding retaining strap to stirrup.

Remove Strap From Stirrup And Gear:

3. Remove strap from output gear and stirrup.

Remove Stirrup From Gear:

Stirrup And Strap Removed From Output Gear:

4. Remove stirrup from output gear.

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

Refer to Bearing Adjustment Procedure at the rear of this section, to determine proper shim thickness. Check output shaft bearing turning torque, using an inch lb. torque wrench. If turning torque is 3 to 8 inch lbs., the proper shim has been installed.

ASSEMBLY

Install Output Shaft Gear Bearing Cone:

Install Rear Planetary Annulus Gear Bearing Cone:

Install Output Shaft Into Rear Planetary Annulus Gear:

Install Output Shaft Gear Bearing Cup:

Install Rear Planetary Annulus Gear Bearing Cup:

Install Output Shaft Assembly:

Output Shaft And (Select) Shims In Position:

Start Output Shaft Gear Onto Output Shaft:

Holding Output Shaft Gear:

Tighten Output Shaft Retaining Nut To 271 Nm (200 Ft. Lbs.):

Checking Output Shaft End Play:

Checking Bearing Turning Torque:

Stirrup And Retaining Strap
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.

Turn Stirrup Clockwise Against Flats Of Retaining Nut:

4. Turn stirrup clockwise against the flats of the output gear retaining nut.

Tighten Strap Retining Nuts:

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