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Dealer Service 19
MAN0155 (Rev. 2/16/2007)
15. Remove bottom bearing (6) by using a punch and
hammer from the top, outside the housing.
Support housing upside down (top cover surface)
and remove second bearing (6) by using a punch
and hammer from the bottom side of the housing.
16. Inspect gears for broken teeth and wear. Some
wear is normal and will show on loaded side.
Forged gear surfaces are rough when new. Check
that wear pattern is smooth.
17. Inspect vertical and horizontal shafts for grooves,
nicks, or bumps in the areas where the seals seat.
Resurface any damage with emery cloth.
18. Inspect housing and caps for cracks or other
damage.
Figure 14. Gearbox Assembly
Gearbox Assembly
Refer to Figure 14.
NOTE: Repair to this gearbox is limited to replacing
bearings, seals, and gaskets. Replacing gears, shafts,
and a housing is not cost effective. Purchasing a com-
plete gearbox is more economical.
1. Clean housing, paying specific attention to areas
where gaskets will be installed.
2. Wash housing and all components thoroughly.
Select a clean area for gearbox assembly. Replace
all seals, bearings, and gaskets. All parts must be
clean and lightly oiled before reassembling.
3. Insert output bearings (6) in the housing, using a
round tube of the correct diameter and a hand
press.
4. Slide output shaft (4) through both bearings (6)
until it rests against top bearing (6).
5. Slide shim (15) over output shaft (4).
6. Press gear (5) onto output shaft (4) and secure
with washer (16), nut (24), and cotter pin (9).
7. Apply grease to lower seal lips (17) and press seal
(17) over output shaft (4), using a tube of the
correct diameter. Be sure not to damage the seal
lip.
Press in housing so that seal is recessed. Insert
protective washer (8) by hand.
8. Press rear bearing (7) into the housing, using a
round tube of the correct diameter and a hand
press. Secure with snap ring (10).
9. Secure snap ring (11) on input shaft (3) if not
already secure.
10. Place gear (1) through top of housing and align
gear (1) and gear (5) so that gear teeth are a
match.
11. While holding gear (1) in place, slide input shaft (3)
through gear (1) and bearing (7). Align splines on
shaft (3) and gear (1).
12. Slide shim (12) over input shaft (3) and secure with
snap ring (10).
13. Check input shaft end float by moving the input
shaft (3) by hand. If end float is higher than 0.012",
insert shim between input shaft (3) and rear
bearing (8). Repeat until end float is less than
0.012". Check rotational torque by hand. The
torque should be less than 2.2 lbs-inch.
14. Check that the gear backlash is between 0.006"
and 0.016". You should not have to adjust the
backlash.
15. Press in input oil seal (18), using tube of correct
diameter. Be careful not to damage seal lip.
16. Slide shim (13) over input shaft (3) and secure with
snap ring (10).
17. Press oil cap (23) on to cover the rear of housing,
using a tube of the correct diameter.
18. Install cover (20).
19. Check gearbox housing for leaks by plugging all
holes except one. Apply 4 psi compressed air and
immerse the gearbox in water to verify that there
are no leaks.
20. Remove gearbox from water and dry off with
compressed air.