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Dealer Service 31
5WPMAN0183 (Rev. 4/25/2008)
diameter. Be sure not to damage the seal lip. Press
in housing so that seal is recessed.
8. Insert protective washer (8) by hand. Install snap
ring (21) and position it together with dual lip seal
(18) by pressing it into position. Verify that snap
ring is seated correctly.
9. Press bearing (7) into the housing, using a round
tube of the correct diameter and a hand press.
Secure with shim (13) and snap ring (10).
10. Secure snap ring (11) on input shaft (3) if not
already secure.
11. Place gear (1) through top of housing and align
gear (1) and gear (5) so that gear teeth are a
match.
12. While holding gear (1) in place, slide input shaft (3)
through gear (1) and bearing (7). Align splines on
shaft (3) and gear (1).
13. Slide spacer (12) over input shaft (3) and press
bearing onto input shaft (3), using a round tube of
the correct diameter and a hand press.
14. Slide shim (13) over input shaft (3) and secure with
snap ring (10).
15. Check input shaft end float by moving the input
shaft (3) by hand. If end float is higher than 0.012"
(0.305 mm), insert shim between input shaft (3)
and rear bearing (7). Repeat until end float is less
than 0.012" (0.305 mm). Check rotational torque by
hand. The torque should be less than 2.2 lbs.-inch
(0.25 N-m).
16. Check that the gear backlash is between 0.006"
and 0.016" (0.152 mm - 0.406 mm). You should not
have to adjust the backlash.
17. Press in input oil seal (19), using tube of correct
diameter. Be careful not to damage seal lip.
18. Press oil cap (20) on to cover the rear of housing,
using a tube of the correct diameter.
19. Check gearbox housing for leaks by plugging all
holes except one. Apply 4 psi (28 kPa) compressed
air and immerse the gearbox in water to verify that
there are no leaks.
20. Remove gearbox from water and dry off with com-
pressed air. Add SAE 80W or 90W EP oil until it
runs out of side level hole. Tighten all plugs.
Figure 20. Gearbox Assembly
1. Crown gear
2. Gearbox housing
3. Input shaft
4. Output shaft
5. Gear pinion
6. Bearing
7. Bearing
8. Protective flat washer
9. Cotter pin
10. Snap ring
11. Snap ring
12. Spacer
13. Shim kit
14. Castle nut
15. Castle nut M24 x 2
16. Shim Kit
17. Flat washer
18. Oil seal (40 x 80 x 12)
19. Oil seal (35 x 72 x 10)
20. Cap
21. Snap ring
22. Top Cover
23. Bolt M8 x 14mm
24. Breather level plug
25. Cotter pin
26. Bearing
27. Ball Bearing