Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.
This component or assembly weighs greater than 23 kg [50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.
Remove the remaining capscrews. Use a rubber hammer to loosen the housing.
With the housing positioned so the cylinder block mating surface is down, use a hammer and brass punch to drive the bearing outer races out of the output shaft housing bore.
This component or assembly weighs greater than 23 kg {50 lb]. To prevent serious personal injury, be sure to have assistance or use appropriate lifting equipment to lift this component or assembly.
Inspect the rear face of the cylinder block and flywheel housing mounting surface for cleanliness and nicks or burrs.
Install the flywheel housing over the two ring dowels.
Be sure the sealing ring is not damaged during installation.
The outer bearing races of new replacement gears are already pressed into the gear.
Apply a thin film of assembly lubricant, Part Number 3163087, or equivalent, on the outer races and bearings.
Install the bearing and spacer into the idler gear. Use the babricated PVC (or equivalent) sleeve to hold the bearing assembly together when installing the idler gear assembly.
Apply a thin film of assembly lubricant, Part Number 3163087, or equivalent, into the idler shaft bore of the housing and on the idler shaft.
NOTE: For idler scissor gears, loosen the screws in the scissor gear by turning counterclockwise until they will no longer turn. The screws will not come out of the gear
Install the idler gear assembly into the flywheel housing.
Hold the idler gear and bearing in place and remove the plastic sleeve.
Apply assembly lubricant, Part Number 3163087, or equivalent, under the head of the idler shaft capscrew. Insert the capscrew through the idler shaft. Tighten the installation capscrew with a torque wrench.
The torque needed to draw the idler shaft in place must not exceed 88 N•m [65 ft-lb]. If installation torque exceeds this amount, it is an indication of misalignment between the bore and the shaft. Remove the idler shaft and install it again.
When the idler shaft has been seated, remove the capscrew.
Apply pipe sealant, Part Number 3375066, to the threads of the idler shaft capscrew. Apply assembly lubricant, Part Number 3163087, or equivalent, under the head of the capscrew and tighten to the final torque value.
Turn the output flange so that the flat sides are on the top and bottom. This prevents any interference when the transmission is installed onto the housing.
Do not use any lubricant to install the seal. The oil seal must be installed with the crankshaft gear seal contact surface and the lip of the seal clean and dry to provide a proper oil sealing surface.
Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.