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
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.
MAN0155 (Rev. 2/16/2007) | Dealer Service 19 |
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