D. Assembly of Front Output Shaft
(See Page PM2 and Page PM3).
Insert plain end of front output shaft (Item 15) into
the clutch gear assembly (Items 11, 12, and 13).
Install the spacer ring (Item 14) and the rear bearing
(Item 15) on the shaft. Slide the clutch (Item 10)
onto the splined end of the shaft and engage its
teeth with those in the clutch gear.
Lower this assembly into the cover opening of the
case housing with the gear at the opposite side of
the housing from the front output opening (See Fig.
9). Guide the threaded shaft end into the front
output (See Fig. 10) opening and swing the gear
end partially into the intermediate shaft rear opening.
This will allow the other end of the shaft to enter the
front output opening. Advance the shaft through the
front output opening enough to permit backing the
bearing into the rear case bearing bore (See Fig.
Slip the front bearing (Item 8) over the end of the
shaft and into the housing bore. The snap ring on
the bearing should be on the outboard side of the
bearing. Tap bearing into place (See Fig. 12).
Install the front output seal carrier gasket (Item 7)
and the seal carrier (Item 5 with Item 4 in place).
Permatex the bolt threads, tighten the bolts (Item 3)
to the specified torque.
Coat the seal surface and splined hole of the front
output yoke with Lubriplate.
Align the yoke on the shaft, tap into place. Install
yoke retaining washer lightly coated with Permatex.
Coated face next to the yoke. Install the locknut and
tighten to specified torque.
Temporarily install the rear cap (See Fig. 13) in
place with all six bolts, but with bolts tightened to 25
lbs. ft. torque. Measure gap between the case
housing and the flange of the cap. Select a shim
stack that is .010 to .015 larger than this dimension.
Remove bolts and cap.
Install shims and cap, coat bolt threads with
Permatex, install and tighten bolts to the specified
Look inside the case and make certain the bearings
are pulled tight against the shaft shoulders. Spin the
shaft to be sure it rotates freely.