Output Shaft Repair

NOTE: Transfer shaft should be removed for repair of output shaft. Planetary gear sets must be removed to accurately check output shaft bearing turning torque.

Remove Output Shaft Retaining Nut And Washer:

Remove Output Shaft Gear:

Output Shaft Gear And (Select) Shim:

Remove Output Shaft Gear Bearing Cone:

Install Output Shaft Gear Bearing Cone:

Remove Output Shaft And Rear Annulus Gear Assembly:

Remove Output Shaft:

Remove Rear Planetary Annulus Gear Bearing Cone:

Install Rear Planetary Annulus Gear Bearing Cone:

Install Output Shaft Into Rear Planetary Annulus Gear:

Remove Output Shaft Gear Bearing Cup:

Remove Rear Planetary Annulus Gear Bearing Cup:

Install Output Shaft Gear Bearing Cup:

Install Rear Planetary Annulus Gear Bearing Cup:

DETERMINING SHIM THICKNESS
Shim thickness need only be determined if any of the following parts are replaced:
- Transaxle case
- Output shaft
- Rear planetary annulus gear
- Output shaft gear
- Rear annulus and output shaft gear bearing cones
- Overrunning clutch race cups.
Refer to Bearing Adjustment Procedure, to determine proper shim thickness. Check output shaft bearings turning torque, using an inch-pound torque wrench. If turning torque is 3 to 8 inch-pounds, the proper shim has been installed.

Install Output Shaft Assembly:

Output Shaft And (Select) Shims In Position:

Start Output Shaft Gear Onto Output Shaft:

Holding Output Shaft Gear:

Tighten Output Shaft Retaining Nut To 271 Nm (200 Ft. Lbs.):

Checking Output Shaft End Play:

Checking Bearings Turning Torque: