D. Assembly of Front Output Shaft(See Page PM2 and Page PM3).1.Insert plain end of front output shaft (Item 15) intothe 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 itsteeth with those in the clutch gear.2.Lower this assembly into the cover opening of thecase housing with the gear at the opposite side ofthe housing from the front output opening (See Fig.9). Guide the threaded shaft end into the frontoutput (See Fig. 10) opening and swing the gearend partially into the intermediate shaft rear opening.This will allow the other end of the shaft to enter thefront output opening. Advance the shaft through thefront output opening enough to permit backing thebearing into the rear case bearing bore (See Fig.11).3.Slip the front bearing (Item 8) over the end of theshaft and into the housing bore. The snap ring onthe bearing should be on the outboard side of thebearing. Tap bearing into place (See Fig. 12).Fig. 9Fig. 10Fig. 11Fig. 124.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.5.Coat the seal surface and splined hole of the frontoutput yoke with Lubriplate.6.Align the yoke on the shaft, tap into place. Installyoke retaining washer lightly coated with Permatex.Coated face next to the yoke. Install the locknut andtighten to specified torque.7.Temporarily install the rear cap (See Fig. 13) inplace with all six bolts, but with bolts tightened to 25lbs. ft. torque. Measure gap between the casehousing and the flange of the cap. Select a shimstack that is .010 to .015 larger than this dimension.Remove bolts and cap.8.Install shims and cap, coat bolt threads withPermatex, install and tighten bolts to the specifiedtorque.9.Look inside the case and make certain the bearingsare pulled tight against the shaft shoulders. Spin theshaft to be sure it rotates freely.-17-
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