Output Shaft: Service and Repair

For removing the output shaft, follow the description for dismantling the gearbox up to the point where the output shaft has been removed. Then continue dismantling as follows:





1. Secure fixture 87 90 446 in a vice and place the output shaft in the fixture. Use spanner 87 90 453 to release the nut.





2. Set up the bearing housing in a press and press the shaft out of the bearing housing. Remove the spacer sleeve.





3. Then use tools 87 90 636 and 87 90 651 to press off the rear roller bearing. Turn the shaft from time to time and check that the tops of the teeth are clear of the tool.





4. Use tools 83 90 098, 83 90 106 and 83 90 148 to press the outer races of the taper roller bearings out of the bearing housing (see figure).





TO ASSEMBLE AND REFIT
After the relevant part has been removed, inspect all dismantled parts and wash them with paraffin (kerosine) or the like. Then proceed as follows to re-assemble:

NOTE: Oil the bearings before assembly.





1. Use tool 87 91 964 and drift 83 90 189 to press the outer race of the taper roller bearing into the bearing housing nearest to the pinion. Use sleeve 87 90 461 and drift 83 90 189 for the outer race of the other bearing.





2. Press the roller bearing nearest to the pinion as far as it will go. Use fixture 87 90 636 and fitting ring 87 91 972.
3. Fit a new spacer to the shaft.
4. Fit the bearing housing.
5. Fit the front roller bearing.





6. Set up the shaft in the press (see figure). Use fixture 87 90 636 and fitting ring 87 91 972 and press slowly, at the same time turning the bearing housing. Continue pressing until resistance is felt.





7. Apply Loctite 270 to the threads and fit a new nut. Set up the shaft in a vice in tool 87 90 446. Use spanner 87 90 453 to tighten the nut until the correct rolling torque is obtained.





Use a torque spanner to measure the rolling torque. Oil the bearing lightly and preload as follows: New bearings to a torque of 2.5 +/- 0.5 Nm (1.8 +/- 0.4 lb ft), and bearings that have been in service for more than 2000 km to 1.3 +/- 0.5 Nm (1.0 +/- 0.4 lb ft).





8. Fit two guide pins 87 90 438 into the gear-case. Then fit the shims, fit the output shaft with the bearing housing, and fit two bolts. Tighten the two bolts lightly, remove the guide pins and fit the other two bolts. Then tighten the four bolts to a torque of 23 - 28 Nm (17 - 21 lb ft). Apply Loctite locking compound to the bolts.