Assembly
1. Clean the components with a suitable solvent and use compressed air to dry all parts. Perform the following before assembly:- Inspect idler gear for damaged or excessively worn teeth.
- Inspect the idler gear shaft for damage or wear.
2. Use Pinion Bearing Cup Replacer T80T-4000-E to press the new bearing cups into the idler gear
3. Install a new (A) bearing onto the idler gear shaft, then install the (B) idler gear, (C) spacer, and the other new (D) bearing.
4. Use Torque Adapter T87C-77000-E to secure the idler gear in the vice.
CAUTION: Use protective plates to prevent damage to the special tool.
5. Use (A) Mainshaft Locknut Wrench T88T-7025-AR along with a (B) 1-5/8 inch socket and install the idler gear shaft nut.
6. Apply the specified transaxle fluid to a new idler gear shaft seal and install it on the idler gear shaft.
- Idler gear shaft seal inner diameter: 40.5 mm (1.594 inch).
7. Turn the idler gear and Torque Adapter over and secure the idler gear in a vice. Measure the preload while tightening the idler gear shaft nut. The preload torque is 128-176 Nm (95-130 ft. lbs.). The preload is 0.03-0.88 Nm (0.3-7 ft. lbs.).
CAUTION: Use protective plates to prevent damage to the idler gear.
NOTE:
- Read the preload when the idler shaft starts to turn.
- Take several measurements and calculate the average value.
8. If the specified preload cannot be obtained within the specified torque, adjust it by selecting the proper spacer from the table below.
NOTE: The preload can be reduced by increasing. the thickness of the spacer (adjusting shims).
Idler Gear Spacers
3.80 mm (0.150 inch)
4.30 mm (0.169 inch)
3.85 mm (0.152 inch)
4.35 mm (0.171 inch)
3.90 mm (0.154 inch)
4.40 mm (0.173 inch)
3.95 mm (0.156 inch)
4.45 mm (0.175 inch)
4.00 mm (0.157 inch)
4.50 mm (0.177 inch)
4.05 mm (0.159 inch)
4.55 mm (0.179 inch)
4.10 mm (0.161 inch)
4.60 mm (0.181 inch)
4.15 mm (0.163 inch)
4.65 mm (0.183 inch)
4.20 mm (0.165 inch)
4.70 mm (0.185 inch)
4.25 mm (0.167 inch)
4.75 mm (0.187 inch)