Oil Pump

DISASSEMBLY
1. Remove seal ring from housing and reaction shaft support.
2. Mark pump housing and support assembly for alignment reference.





3. Remove bolts attaching pump body to support.





4. Separate support from pump housing.





5. Remove inner and outer gears from reaction shaft support.
6. If pump seal was not removed during transmission disassembly, remove seal with punch and hammer.





7. Remove front clutch thrust washer from support hub.





OIL PUMP BUSHING REPLACEMENT
1. Remove pump bushing with Tool Handle C-4171 and Bushing Remover SP-3551 from Tool Set C-3887-d, or equivalents.
2. Install new pump bushing with Tool Handle C-4171 and Bushing Installer SP-5117, or equivalents. Bushing should be flush with pump housing bore.





3. Stake new pump bushing in two places with blunt punch. Remove burrs from stake points with knife blade afterward.





REACTION SHAFT SUPPORT BUSHING REMOVAL
1. Assemble Bushing Remover Tools SP-1191, 3633 and 5324, or equivalents. Do not clamp any part of reaction shaft or support in vise.
2. Hold Cup Tool SP-3633 firmly against reaction shaft and thread remover SP-5324, or equivalent into bushing as far as possible by hand. Then thread remover tool 3-4 additional turns into bushing with a wrench.
3. Turn remover tool hex nut down against remover cup to pull bushing from shaft. Clean all chips from shaft after bushing removal.
4. Lightly grip old bushing in vise or with pliers and back remover tool out of bushing.
5. Assemble Bushing Installer Tools C-4171 and SP-5325, or equivalents.
6. Slide new bushing onto Installer Tool SP-5325, or equivalent.
7. Position reaction shaft support upright on a clean smooth surface.
8. Align bushing in bore. Then tap bushing into place until Bushing Installer SP-5325, or equivalent bottoms.
9. Clean reaction shaft support thoroughly after installing bushing.

INSPECTION
1. Clean pump and support components with solvent and dry them with compressed air.
2. Check condition of the seal rings and thrust washer on the reaction shaft support. The seal rings do not need to be replaced unless cracked, broken, or severely worn.
3. Inspect the pump and support components. Replace the pump or support if the seal ring grooves or machined surfaces are worn, scored, pitted, or damaged. Replace the pump gears if pitted, worn chipped, or damaged.
4. Inspect the pump bushing. Then check the reaction shaft support bushing. Replace either bushing only if heavily worn, scored or damaged. It is not necessary to replace the bushings unless they are actually damaged.
5. Install the gears in the pump body and measure pump component clearances as follows:
a. Clearance between outer gear and reaction shaft housing should be 0.010 to 0.063 mm (0.0004 to 0.0025 inch). Clearance between inner gear and reaction shaft housing should be 0.025 to 0.177 mm (0.001 to 0.007 inch). Both clearances can be measured at the same time by:
1. Installing the pump gears in the pump housing.
2. Position an appropriate piece of Plastigage across both gears.
3. Align the plastigage to a flat area on the reaction shaft housing.
4. Install the reaction shaft to the pump housing.
5. Separate the reaction shaft housing from the pump housing and measure the Plastigage following the instructions supplied with it.
b. Clearance between inner gear tooth and outer gear should be 0.08 to 0.19 mm (0.0035 to 0.0075 inch). Measure clearance with an appropriate feeler gauge.
c. Clearance between outer gear and pump housing should also be 0.010 to 0.19 mm (0.0035 to 0.0075 inch). Measure clearance with an appropriate feeler gauge.

ASSEMBLY
1. Lubricate gear bore in pump housing with transmission fluid.
2. Lubricate pump gears with transmission fluid.





3. Support pump housing on wood blocks.
4. Install outer gear in pump housing. Gear can be installed either way (it is not a one-way fit).





5. Install pump inner gear.

CAUTION: The pump inner gear is a one way fit. The bore on one side of the gear Inside Diameter (I.D.) is chamfered. Be sure the chamfered side faces forward (to front of pump).

6. Install new thrust washer on hub of reaction shaft support. Lubricate washer with transmission fluid or petroleum jelly.





7. If reaction shaft seal rings are being replaced, install new seal rings on support hub. Lubricate seal rings with transmission fluid or petroleum jelly after installation. Squeeze each ring until ring ends are securely hooked together.

CAUTION: The reaction shaft support seal rings will break if overspread, or twisted. If new rings are being installed, spread them only enough for installation. Also be very sure the ring ends are securely hooked together after installation. Otherwise, the rings will either prevent pump installation, or break during installation.





8. Install reaction shaft support on pump housing.
9. Align reaction support on pump housing. Use alignment marks made at disassembly. Or, rotate support until bolt holes in support and pump housing are all aligned (holes are offset for one-way fit).
10. Install all bolts that attach support to pump housing. Then tighten bolts finger tight.
11. Tighten support-to-pump bolts to required torque as follows:
a. Reverse pump assembly and install it in transmission case. Position pump so bolts are facing out and are accessible.
b. Secure pump assembly in case with 2 or 3 bolts, or with pilot studs.
c. Tighten support-to-pump bolts to 20 Nm (15 ft. lbs.).
d. Remove pump assembly from transmission case.





12. Install new oil seal in pump with Special Tool C-4193 and Tool Handle C-4171, or equivalent Be sure seal lip faces inward.
13. Install new seal ring around pump housing. Be sure seal is properly seated in groove.
14. Lubricate lip of pump oil seal and O-ring seal with transmission fluid.