Harley Davidson 1999-2005 Harley Dyna Models. Repair Manual — page 13
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240
CHAPTER SIX
31
32
Inspection
33
1. Inspect each shift fork (Figure 31) for excessive
wear or damage. Replace worn or damaged shift
forks as required.
2. Measure the thickness of each shift fork finger
(A, Figure 32) where it contacts the sliding gear
groove (Figure 33). Replace any shift fork with a
finger thickness worn to the specification in Table 2.
3. Check the shift forks for arc-shaped wear or burn
marks (B, Figure 32). Replace damaged shift forks.
4. Roll the shift fork shaft on a flat surface and
check for bending. Replace the shaft if bent.
5. Install each shift fork on the shift shaft. The shift
fingers must slide smoothly with no binding or
roughness.
Assembly
34
Refer to Figure 34 to identify the transmission
gears.
Mainshaft
1. Coat all bearing and sliding surfaces with assem-
bly oil.
2. To install the shift forks and shaft (Figure 28),
perform the following:
a. Insert the No. 1 shift fork into the mainshaft
first gear groove.
Countershaft
b. Install the No.
2
shift fork into the
countershaft third gear groove.
c. Install the No. 3 shift fork into the mainshaft
second gear groove.
3. Insert the shift shaft through the transmission
case (A, Figure 29), through each of the three shift
forks and into the transmission case.
4. Install the transmission side door as described in
this chapter.
4th
1st
3rd
2nd
5th
5. Check that the shift forks move smoothly when
shifting the gears by hand.
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TRANSMISSION
241
35
36
37
6
6. Install the shifter cam as described in this chapter.
3. Remove the primary chaincase cover as de-
scribed in Chapter Five.
4. Remove the clutch release cover and clutch as-
TRANSMISSION SIDE DOOR AND
sembly as described in Chapter Five.
TRANSMISSION SHAFT ASSEMBLIES
5. Remove the primary chaincase housing as de-
scribed in Chapter Five.
The transmission side door and transmission
6. Remove the shift forks as described in this chapter.
shaft assemblies can be serviced with the transmis-
7. Remove the bearing inner race (Figure 35) from
sion installed in the frame.
the mainshaft, and perform the following:
a. Attach the mainshaft bearing race puller and
installation tool (Figure 36) against the inner
Removal
bearing race (A, Figure 37), following the
manufacturer’s instructions.
This section describes removal of the transmis-
b. Tighten the puller bolt (B, Figure 37) and
sion and side door assembly.
withdraw the inner race from the mainshaft.
1. Remove the exhaust system as described in
8. Remove the pushrod assembly (B, Figure 29).
Chapter Seven.
9. Turn the transmission by hand and shift the
2. Drain the transmission oil as described in Chap-
transmission into two different gears to lock the
ter Three.
transmission in place.
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242
CHAPTER SIX
38
39
10. If the transmission gear assemblies are going to
be removed from the side door, loosen, but do not
40
remove, the countershaft and mainshaft locknuts
(A, Figure 38).
Mainshaft
11. If the main drive gear is going to be removed,
remove the drive sprocket as described under Drive
Sprocket in Chapter Nine.
12. Remove the bolts securing the exhaust system
Bearing inner race
Extension shaft
mounting bracket
(B, Figure
38). Remove the
bracket.
13. Remove the bolts securing the transmission
side door (C, Figure 38) to the transmission case.
Installation
CAUTION
1. If the main drive gear was removed, install it as
When removing the transmission side
described in this chapter.
door in Step 14, do not tap against the
2. Remove all gasket residue from the side door
transmission shafts from the opposite
side. Doing so will damage the side
and transmission case mating surfaces.
door bearings.
3. Install a new gasket onto the transmission case.
If removed, install the locating pins.
4. Install the side door and transmission assembly
14. Tap against the transmission side door to
into the transmission case. Check that the side door
loosen its seal against the transmission case.
fits flush against the transmission case.
15. Install the transmission door bearing puller
5. Install the transmission side door 5/16 in. and
(Figure 39) onto the door, following the manufac-
1/4 in. bolts finger-tight. Tighten the 5/16 in. bolts
turer’s instructions. Tighten the outside screws 1/2
to the specifications in Table 3. Then do the same
turn at a time, alternating from side-to-side until
for the 1/4 in. bolts.
the door releases from the transmission case. Re-
6. Turn the transmission by hand and shift the
move the special tool.
transmission into two different gear speeds to lock
the transmission from rotation.
16. Slowly withdraw the transmission side door
and the transmission gear assemblies from the
7. To install the bearing inner race (Figure 35) onto
transmission case.
the mainshaft, perform the following:
a. The bearing inner race is
0.950-1.000 in.
17. Remove the transmission side door gasket. Do
(24.13-25.40 mm) long. When installing a
not lose the locating pins.
new race, measure it to confirm its length.
18. If necessary, service the side door and transmis-
Race length determines its final installation
sion assembly as described in this chapter.
position.
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TRANSMISSION
243
41
TRANSMISSION
1. Mainshaft first gear
2. Mainshaft
3. Snap ring
4. Thrust washer
5. Mainshaft third gear
6. Mainshaft second gear
7. Split bearings
8. Oil slinger assembly
9. Clutch pushrod
10. Locknut
11. Washer
12. Side door
13. Gasket
14. Spacer
6
15. Mainshaft fourth gear
16. Spacer
17. Countershaft fourth gear
18. Countershaft first gear
19. Countershaft
20. Countershaft third gear
21. Countershaft second
gear
22. Countershaft fifth gear
b. Use the same tool setup used for bearing inner
0.100-0.150
in.
(2.540-3.810
mm.) away
race removal.
from the main drive gear.
c. Apply clean oil to the transmission shaft bear-
h. Remove the special tools.
ing surface, shaft threads and to the inner sur-
8. Install the pushrod assembly (B, Figure 29).
face of the inner race.
9. Install the shift forks as described in this chapter.
d. Position the bearing inner race with the
10. Install the primary chaincase housing as de-
chamfered end going on first and slide it onto
scribed in Chapter Five.
the mainshaft (Figure 40).
11. Install the clutch assembly and clutch release
cover as described in Chapter Five.
e. Install the extension shaft onto the mainshaft.
12. Install the primary chaincase cover as de-
f. Place the pusher tube over the extension
scribed in Chapter Five.
shaft, along with the two flat washers and nut.
13. Install the drain plug and refill the transmission
CAUTION
oil as described in Chapter Three.
Install the inner bearing race to the
14. Install the bolts securing the exhaust system
dimension listed in substep g. This
mounting bracket (B, Figure 38) and tighten se-
will align the race with the bearing
curely.
outer race installed in the primary
15. Install the exhaust system as described in
chaincase. Installing the wrong race
Chapter Seven.
or installing it incorrectly will dam-
16. Test ride the motorcycle slowly and check for
age the bearing and race assembly.
proper transmission operation.
g. Hold the extension shaft and tighten the nut to
press the bearing inner race onto the
TRANSMISSION SHAFTS
mainshaft. The mainshaft and countershaft
nuts have left-hand threads. Turn the
This section describes service to the side door and
mainshaft nut counterclockwise to tighten it.
both transmission shaft assemblies.
Install the race so that its inside edge is
Refer to Figure 41.
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244
CHAPTER SIX
42
44
43
45
Transmission Disassembly
46
The transmission shaft assemblies must be par-
tially disassembled prior to removing both shafts
from the side door. Do not try to remove the shafts
with all of the gears in place.
Store all of the transmission gears, snap rings,
washers and split bearings in their order of removal.
The snap rings are very difficult to loosen and re-
move, even with high-quality snap ring pliers. A
heavy-duty type retaining ring pliers (H-D part No.
J-5586), or an equivalent, are recommended for this
procedure.
1. Remove the transmission side door and transmis-
47
sion shaft assemblies as described in this chapter.
2. Protect the splines and threads on the mainshaft
with tape or a plastic sleeve (Figure 42).
3. Remove the mainshaft second gear (Figure 43).
4. Remove the snap ring (Figure 44) from the
countershaft.
5. Remove the countershaft fifth gear (Figure 45).
6. Remove the countershaft second gear (Figure
46).
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TRANSMISSION
245
48
52
49
53
6
CAUTION
50
Do not expand the split bearings any
more than necessary to slide them off
the shaft. The bearing carriers are
plastic and will fracture if expanded
too far.
7. Remove the split bearing (Figure 47) from the
countershaft.
8. Slide off the washer and remove the snap ring
(Figure 48) from the countershaft.
9. Remove the countershaft third gear (Figure 49).
NOTE
The snap ring in Step 10 must be re-
51
leased and moved in order to gain ac-
cess to the snap ring on the other side
of the third gear.
10. Using snap ring pliers, release the snap ring
(Figure 50) behind the mainshaft third gear. Slide
the snap ring away from the third gear.
11. Slide the third gear toward the side door and re-
move the snap ring (Figure 51) and washer.
12. Remove the mainshaft third gear (Figure 52).
13. Remove the washer and snap ring (Figure 53).
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246
CHAPTER SIX
54
55
14. Remove the split bearing (Figure 54) from the
mainshaft.
56
15. Place a brass or aluminum washer (Figure 55)
between the countershaft fourth gear and the
mainshaft fourth gear. This will lock both transmis-
sion shafts from rotation.
16. Loosen and remove the locknuts and washers
(Figure 56) securing the shaft assemblies to the side
door. Remove the brass or aluminum washer. New
locknuts must be installed during assembly.
17. Press the countershaft out of its side door bear-
ing as follows:
a. Support the countershaft first gear on a tube
(A, Figure
57) in a press so that the
57
countershaft can be pressed out without any
interference. Center the countershaft under
the press ram.
b. Place a mandrel (B, Figure 57) on top of the
countershaft and press the countershaft out of
the side door.
18. Remove the spacer (A, Figure 58), fourth gear
(B), first gear
(C) and washer
(D) from the
countershaft.
19. Remove the split bearing (A, Figure 59) from
the countershaft.
20. If necessary, remove the snap ring (B, Figure
59) from the countershaft.
58
21. Remove the first gear (Figure 60) from the
mainshaft.
22. Remove the snap ring and washer (A, Figure
61) from the mainshaft.
23. Press the mainshaft out of its side door bearing
as follows:
a. Support the mainshaft fourth gear on a tube
(A, Figure 62) in a press so that the mainshaft
can be pressed out without any interference.
Center the mainshaft under the press ram.
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TRANSMISSION
247
59
63
b. Place a mandrel (B, Figure 62) on top of the
60
mainshaft and press the mainshaft out of the
6
side door.
24. From the mainshaft, remove the fourth gear and
spacer (B, Figure 61).
25. Inspect all parts as described in this section.
Transmission Inspection
Maintain the alignment of the transmission com-
ponents when cleaning and inspecting the individ-
ual parts in the following section. To prevent
intermixing parts, work on only one shaft at a time.
61
Refer to Table 2 and inspect the service clearance
and end play of the indicated gears and shafts. Re-
place parts that show excessive wear or damage as
described in this section.
CAUTION
Do not clean the split bearings in sol-
vent. It is difficult to remove all traces
of solvent from the bearing plastic re-
tainers. Flush the bearings clean with
new transmission oil.
1. Clean and dry the shaft assembly.
2. Inspect the mainshaft and countershaft for:
62
a. Worn or damages splines (A, Figure 63).
b. Excessively worn or damaged bearing sur-
faces.
c. Cracked or rounded-off snap ring grooves (B,
Figure 63).
d. Worn or damaged threads (C, Figure 63).
3. Check each gear for excessive wear, burrs, pit-
ting, and chipped or missing teeth. Check the inner
splines (Figure 64) on sliding gears and the bore on
stationary gears for excessive wear or damage.
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248
CHAPTER SIX
4. Check the gear bushings (Figure 65) for wear,
cracks or other damage.
64
5. To check stationary gears for wear, install them
on their correct shaft and in the original operating
position. If necessary, use the old snap rings to se-
cure them in place. Then spin the gear by hand.
The gear should turn smoothly. A rough turning
gear indicates heat damage—check for a dark blue
color or galling on the operating surfaces. Rocking
indicates excessive wear, either to the gear or shaft
or both.
6. To check the sliding gears, install them on their
correct shaft and in their original operating position.
The gear should slide back and forth without any
65
binding or excessive play.
7. Check the shift fork slot (Figure 66) for wear or
damage.
8. Check the dogs on the gears for excessive wear,
rounding, cracks or other damage. Refer to Figure
67. When wear is noticeable, make sure it is consis-
tent on each gear dog. If one dog is worn more than
the others, the others will be overstressed during op-
eration and will eventually crack and fail. Check en-
gaging gears as described in Step 9.
9. Check each gear dog slot for cracks, rounding
and other damage. Check engaging gears as de-
66
scribed in Step 6.
10. Check engaging gears by installing the two
gears on their respective shafts and in their original
operating position. Mesh the gears together. Twist
one gear against the other and then check the dog
engagement. Then reverse the thrust load to check
in the other operating position. Make sure the en-
gagement in both directions is positive and without
any slippage. Check that there is equal engagement
across all of the engagement dogs.
NOTE
When there is excessive or uneven
67
wear to the gear engagement dogs,
check the shift forks carefully for
bending and other damage. Refer to
Shifter Adjustment in this chapter.
NOTE
Replace defective gears along with
their mating gears, though they
may not show as much wear or dam-
age.
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TRANSMISSION
249
68
70
3. Remove both snap rings (Figure 73) from the
69
outer surface of the side door.
6
4A. If the special tool set is used, follow the manu-
facturer’s instructions and remove the bearings.
4B. If a press is used, perform the following:
a. Support the side door on the press bed with
the outer surface facing up.
b. Use a driver or socket and press the bearing
out of the backside of the side door.
c. Repeat for the opposite bearing.
5. Clean the side door again in solvent and dry thor-
oughly.
11. Check the spacers (Figure 68) for wear or dam-
6. Inspect the bearing bores in the side cover for
age.
cracks or other damage. Replace the side door if
12. Check the split bearings (Figure 69) for exces-
damaged.
sive wear or damage.
13. Replace all of the snap rings during reassembly.
NOTE
In addition, check the washers for burn marks, scor-
Both side door bearings have the
ing or cracks. Replace as necessary.
same part number.
7A. If the special tool set is used, follow the manu-
Side Door Bearings
facturer’s instructions and install the bearings.
Inspection and Replacement
7B. If a press is used, perform the following:
a. Support the side door in a press with the back-
The side door bearings are pressed into place and
side facing up.
secured with a snap ring. They can be removed and
installed using a special transmission door bearing
b. Install bearings with their manufacturer’s
remover and installer tool set (JIMS part No. 1078)
marks facing out.
(Figure 70). If the special tool set is not available, a
c. Use a driver that matches the bearing outer
press is required.
race. Press the bearing into the side door until
Refer to Figure 71.
it bottoms.
1. Clean the side door and bearings in solvent and
d. Repeat for the opposite bearing.
dry with compressed air.
8. Position the beveled snap ring with the sharp
2. Turn each bearing inner race (Figure 72) by
side facing toward the bearing outer race and install
hand. The bearings must turn smoothly.
the snap ring. Make sure the snap ring is correctly
If replacement is necessary, continue to Step 3.
seated in the side door groove (Figure 73).
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250
CHAPTER SIX
71
TRANSMISSION CASE BEARINGS AND COVERS
1.
Locating pin
2.
Transmission case
3.
Mainshaft
bearing-left side
4.
Snap ring
5.
Quad seal
6.
Oil seal
7.
Sprocket spacer
8.
Spacer (1999-2000)
9.
Bearing
10.
Transmission side
door
11.
Gasket
12.
Bolt
13.
Bolt
14.
Locknut
15.
Washer
16.
Bolt
17.
Bolt
18.
Washer
19.
Bolt
20.
Washer
21.
Harness retainer
22.
Gasket
23.
Coupling
24.
Ball (3)
25.
Inner ramp
26.
Filler plug/dipstick
27.
O-ring
28.
Clutch release
cover
29.
Bolt
30.
Clutch cable
31.
Plug
32.
Outer ramp
72
73
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TRANSMISSION
251
74
TRANSMISSION
1. Mainshaft first gear
2. Mainshaft
3. Snap ring
4. Thrust washer
5. Mainshaft third gear
6. Mainshaft second gear
7. Bearings
8. Oil slinger assembly
9. Clutch pushrod
10. Locknut
11. Washer
12. Side door
13. Gasket
14. Spacer
6
15. Mainshaft fourth gear
16. Spacer
17. Countershaft fourth
gear
18. Countershaft first gear
19. Countershaft
20. Countershaft third gear
21. Countershaft second
gear
22. Countershaft fifth gear
Transmission Assembly
75
Refer to Figure 74.
CAUTION
Install a new snap ring at every loca-
tion to ensure proper gear alignment
and engagement. Never reinstall a
snap ring that has been removed,
since it has become distorted and
weakened and may fail. Make sure
each new snap ring is correctly seated
in its respective shaft groove.
1. Apply a light coat of clean transmission oil to all
76
mating gear surfaces and to all split bearing halves
before assembly.
2. If removed, install the side door bearings as de-
scribed in this chapter.
3. Onto the mainshaft, install the following:
a. If removed, install the new snap ring (Figure
75).
b. Position the first gear with the shift dog side
going on last and install the first gear (Figure
76).
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252
CHAPTER SIX
77
79
78
80
c. Install the snap ring
(A, Figure 77) and
washer (B).
81
d. Install the split bearing (Figure 78).
e. Position the fourth gear with the shift dog side
going on first and install the fourth gear (Fig-
ure 79).
f. Position the spacer with the beveled side fac-
ing out (Figure 80) and install the spacer.
4. Onto the countershaft, install the following:
a. If removed, install the new snap ring (A, Fig-
ure 81).
b. Install the washer (B, Figure 81) and push it
against the snap ring.
c. Install the split bearing (Figure 82).
82
d. Position the first gear with the shoulder side
(Figure 83) going on last and install the first
gear onto the split bearing (Figure 84).
e. Position the fourth gear with the wide shoul-
der (Figure 85) going on first and install the
fourth gear.
f. Position the spacer with the beveled side fac-
ing out (Figure 86) and install the spacer.
5. Apply transmission oil to the inner race of both
bearings and onto the shoulder of both shaft assem-
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TRANSMISSION
253
83
87
84
88
6
85
89
blies. Also apply transmission oil to the inner
86
threads and ends of the special tools used in Step 8.
6. Position the countershaft (A, Figure 87) on the
left side of the side door. Position the mainshaft (B,
Figure 87) on the right side of the side door.
7. Mesh the two shaft assemblies together and start
them into the side door bearings (Figure 88).
8. Attach the shaft installers (JIMS part No. 2189)
onto the ends of both shafts.
9. Tighten the special tools (Figure 89), alternating
between both shafts, until both shaft shoulders bot-
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254
CHAPTER SIX
90
92
91
93
tom on the inner race of the side door bearings (Fig-
ure 90).
94
10. Unscrew and remove the special tools.
CAUTION
Always install new locknuts. If an old
locknut is reinstalled, it may work
loose, resulting in costly transmission
damage.
11. Install the spacers
(A, Figure 91) and new
locknuts (B).
12. Start the new locknuts by hand until the locking
portion of the nut touches the end of the transmis-
sion shaft.
95
13. Place a brass or aluminum washer (Figure 55)
between the countershaft fourth gear and the
mainshaft fourth gear. This will lock both transmis-
sion shafts.
14. Tighten the locknuts (Figure 92) to the specifi-
cation in Table 3.
15. Onto the mainshaft, install the following:
a. Install the split bearing (Figure 93).
b. Move the snap ring (A, Figure 94) installed in
Step 3 out of the groove and toward the first gear.
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TRANSMISSION
255
96
100
97
101
6
c. Install the washer (B, Figure 94) and slide it
98
against the snap ring (A, Figure 95).
d. Position the third gear with the shift dogs side
(B, Figure 95) going on last. Install the third
gear onto the split bearing (Figure 96).
e. Install the washer (A, Figure 97) and snap
ring (B). Make sure the snap ring is correctly
seated in the mainshaft groove.
f. Move the third gear away from the first gear
and up against the washer and snap ring in-
stalled in sub-step e.
g. Reposition the washer and snap ring (A, Fig-
ure
95) behind the third gear into the
mainshaft groove. Make sure the snap ring is
99
correctly seated in the mainshaft groove.
16. Onto the countershaft, install the following:
a. Position the third gear with the shift fork
groove (Figure 98) side going on last and in-
stall the third gear.
b. Install the circlip (A, Figure 99) and washer
(B).
c. Install the split bearing (Figure 100).
d. Position the second gear with the shift dog
side (Figure 101) going on first. Install the
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256
CHAPTER SIX
102
105
103
106
104
107
second gear onto the split bearing (Figure
102).
108
17. Onto the mainshaft, position the second gear
with the shift fork groove (Figure 103) side going
on first and install the second gear (Figure 104).
18. Onto the countershaft, install the fifth gear
(Figure 105), then install the snap ring (Figure
106). Make sure the snap ring is correctly seated in
the countershaft groove.
19. Refer to Figure 107 for correct placement of all
gears. Also check that the gears mesh properly to
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TRANSMISSION
257
109
MAIN DRIVE GEAR
6
1. Bearing
6. Snap ring
2. Main drive gear
7. Quad seal
3. Transmission case
8. Oil Seal
4. Bearing
9. Sprocket spacer
5. Mainshaft bearing-
left side
the adjoining gear where applicable. This is the last
Removal
chance prior to installing the shaft assemblies into
the transmission case. Make sure they are correctly
1. Remove the transmission shaft assemblies from
assembled.
the transmission case as described in this chapter.
2. Remove the spacer from the main drive gear oil
seal.
MAIN DRIVE GEAR
3. Remove the snap ring behind the bearing.
The main drive gear and bearing assembly are
NOTE
pressed into the transmission case. If the transmis-
If the main drive gear will not loosen
sion case is installed in the frame, a special trans-
from the bearing in Step 4 due to cor-
mission main drive gear tool set (JIMS part No.
rosion, remove the special tools and
35316-80) is required to remove the main drive gear
heat the bearing with a heat gun.
(Figure 108). If the transmission has been removed,
use a press to remove and install the main drive
4. Assemble the special tool set onto the main drive
gear.
gear following the manufacturer’s instructions.
Whenever the main drive gear is removed, the
Then tighten the puller nut slowly to pull the main
main drive gear bearing must be replaced at the
drive gear from the bearing in the transmission case.
same time.
5. Remove the main drive gear bearing from the
Refer to Figure 109.
transmission case as described in this section.
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258
CHAPTER SIX
Inspection
110
1. Clean the main drive gear in solvent and dry with
compressed air, if available.
2. Check each gear tooth (A, Figure 110) for ex-
cessive wear, burrs, galling and pitting. Check for
missing teeth.
3. Check the gear splines (B, Figure 110) for ex-
cessive wear, galling or other damage.
4. Inspect the two main drive gear needle bearings
for excessive wear or damage. Refer to Figure 111
and Figure 112. Insert the mainshaft into the main
drive gear to check bearing wear. If necessary, re-
place the bearings as described in this section.
111
Main Drive Gear Needle Bearing
Replacement
Both main drive gear needle bearings must be in-
stalled to the correct depth within the main drive
gear. The correct depth is obtained with the use of a
main drive gear bearing tool
(JIMS part No.
37842-91). This tool is also used to install the oil
seal. If this tool is not available, a press is required.
If this tool is not available, measure the depth of
both bearings before removing them.
Replace both main drive gear needle bearings as a
112
set.
CAUTION
Never re-install a main drive gear
needle bearing, as it was distorted
during removal.
1. Remove the oil seal (Figure 113) from the clutch
side of the main drive gear.
2. If the special tool is not used, measure and re-
cord the depth of both bearings.
3. Support the main drive gear in a press and press
out one needle bearing. Then turn the gear over and
press out the opposite bearing.
113
4. Clean the gear and its bearing bore in solvent and
dry thoroughly.
5. Apply transmission oil to the bearing bore in the
main drive gear and to the outer surface of both
bearings.
NOTE
Install both needle bearings with their
manufacturer’s name and size code
facing out.
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TRANSMISSION
259
installation tool, with the short side facing
114
down (Figure 115), inserted into the bearing.
Operate the press until the tool’s shoulder
bottoms against the gear.
c. Turn the main drive gear over so that the inner
end faces up. Align the new bearing with the
main drive gear and place the installation
tool, with the long side facing down, inserted
into the bearing. Operate the press until the
tool’s shoulder bottoms against the gear.
6B. If the bearings are being installed without the
installation tool, use a suitable mandrel and press in
the bearing to the depth recorded in Step 2.
7. Install a new oil seal (Figure 113) into the clutch
115
side of the main drive gear.
6
Main Drive Gear Bearing Replacement
The main drive gear bearing (Figure 109) is
pressed into the transmission case. If the transmis-
sion case is installed in the frame, a transmission
main bearing remover set (JIMS part No. 1720)
(Figure 116), or equivalent, is required to remove
the main drive gear bearing.. If the transmission has
been removed, use a press to remove the main drive
gear bearing.
Whenever the main drive gear is removed, the
116
main drive gear bearing is damaged and must be re-
placed at the same time.
CAUTION
Failure to use the correct tools to install
the bearing will cause premature fail-
ure of the bearing and related parts.
1. Remove the main drive gear from the transmis-
sion case as described in this chapter.
2. Assemble the special tool set onto the main drive
gear bearing following the manufacturer’s instruc-
6A. To install the bearings with the special tool, per-
tions. Then tighten the bolt and nut slowly to pull the
form the following steps:
main drive gear bearing from the transmission case.
3. Clean the bearing bore and dry with compressed
a. The special tool has two different length ends.
air. Check the bore for nicks or burrs. Check the
The tool’s long side (A, Figure 114) is for the
snap ring groove for damage.
clutch side of the main drive gear (Figure
112). The tool’s short side (B, Figure 114) is
NOTE
for the transmission side of the main drive
Install the bearing into the transmis-
gear (Figure 111).
sion case with the bearing manufac-
turer’s name and size code facing out.
b. Install the main drive gear in a press with the
transmission end facing up. Align the new
4. Apply transmission oil to the bearing bore in the
bearing with the main drive gear and place the
transmission case and to the outer surface of the
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