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INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the input gear (6). Minor nicks can be dressed off with an oilstone but replace the gear if any
teeth are broken, cracked, or chipped. The bearing surface on the gear can besmoothedwith300-400gritemery
cloth if necessary.
Examine the planetary carrier body (1) and pinion gears for wear or damage.The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion gears are damaged.
Check the carrier lock ring (4) and both thrust washers (2, 3) for wear or cracks. Replace them if necessary. Also
replace the lock retaining ring if bent, distorted, or broken.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork shift
rail (2). Minor nicks on the shift rail can be smoothed
with 320-400 grit emery cloth.
Input Gear and Carrier Components
1 - PLANETARY CARRIER 4 - CARRIER LOCK RING
2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER 6 - INPUT GEAR
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Inspect the shift fork wear pads (3, 4). The mode (2)
and range (1) fork pads are serviceable and can be
replaced if necessary.
Check both of the sleeves for wear or damage, espe-
cially on the interior teeth. Replace the sleeves if wear
or damage is evident.
REAR EXTENSION HOUSING
Inspect the extension housing seal and bushing. Replace both components if either show any sign of wear or dam-
age.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
Inspect the shaft threads, sprocket teeth, and bearing surfaces. Minor nicksontheteethcanbesmoothedwithan
oilstone. Use 320-400 grit emery to smooth minor scratches on the shaft bearing surfaces. Rough threads on the
shaft can be chased if necessary. Replace the shaft if the threads are damaged, bearing surfaces are scored, or if
any sprocket teeth are cracked or broken.
Examine the drive chain and shaft bearings. Replace the chain and both sprockets if the chain is stretched, dis-
torted, or if any of the links bind. Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear (2) condition carefully. The gear
is only serviced as part of the front case (1). If the
gear is damaged, it will be necessary to replace the
gear and front case as an assembly. Do not attempt to
remove the gear.
FRONT AND REAR CASES
Inspect the cases for wear and damage.
Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also
make sure the front case mounting studs are in good condition.
Check the front case mounting studs and vent tube. The tube can be secured with Loctite™ 271 or 680 if loose.
Thestudthreadscanbecleanedupwithadieifnecessary.Alsocheckcondition of the fill/drain plug threads in the
rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired with
Helicoil
stainless steel inserts if required.
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OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the pump if any part appears to beworn or damaged. Do not disas-
semble the pump as individual parts are not available. The pump is only available as a complete assembly. The
pickup screen, hose, and tube are the only serviceable parts and are available separately.
ASSEMBLY
BEARINGS AND SEALS
1. Remove the input shaft bearing (1) from the front
case (2) with suitable snap-ring pliers.
2. Transfer the retaining ring to the new bearing if
necessary and install the bearing into the front
case.
3. Using Bearing Installer 6436 (2) and Universal
Handle C-4171 (3), remove front output shaft bear-
ing.
4. Start front output shaft bearing in case. Then seat
bearing with Universal Handle C-4171 and Bearing
Remover/Installer 6953.
5. Install front output shaft bearing retaining ring.
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6. Remove input gear (2) pilot bearing by inserting a
suitably sized drift (1) into the splined end of the
input gear and driving the bearing out with the drift
andahammer.
7. Install new pilot bearing with Bearing Installer 8684.
8. Remove the front output shaft rear bearing with the
screw and jaws from Remover L-4454 (2) and Cup
8148 (3).
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9. Install new bearing with Universal Handle C-4171
and Bushing Installer 5066.
10. The bearing bore is chamfered at the top. Install
the bearing (1) so it is flush with the lower edge of
this chamfer (2).
11. Remove the rear output shaft bearing from the
rear case (1) using Bearing Installer 8684 (2) and
Universal Handle C-4171 (3).
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12. Install the rear output shaft bearing into the rear
case (1) using Bearing Remover/Installer 6953 (2)
and Universal Handle C-4171 (3).
INPUT AND PLANETARY GEAR
1. Lubricate gears (4) and thrust washers (5) with rec-
ommended transmission fluid.
2. Install first thrust washer in low range gear (5). Be
sure washer tabs are properly aligned in gear
notches.
3. Install input gear (3) in low range gear (4). Be sure
input gear is fully seated.
4. Install remaining thrust washer (5) in low range
gear (4) and on top of input gear (3). Be sure
washer tabs are properly aligned in gear notches.
5. Install retainer (2) on input gear and install snap-
ring (1).
6. Align and install low range/input gear assembly (2)
in front case (1). Be sure low range gear pinions
are engaged in annulus gear and that input gear
shaft is fully seated in front bearing.
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7. Install snap-ring (2) to hold input/low range gear (1)
into front bearing.
8. Install a new input gear seal using Installer 8841
and Universal Handle C-4171.
SHIFT FORKS AND MAINSHAFT
1. Lubricate mainshaft splines with recommended
transmission fluid.
2. Install the mode hub (2) onto the output shaft (1).
3. Install the mode hub retaining ring (2) onto the out-
put shaft (1).
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4. Install the sprocket hub (2) onto the output shaft
(1).
5. Install the clutch gear (2) onto the output shaft (1).
6. Install the drive sprocket (2) onto the output shaft
(1).