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DISASSEMBLE GEARBOX
(Figure 16)
1. Remove vent plug (24) of gearbox and pour out re-
maining gear oil.
2. Support housing in vise with the input shaft in a hor-
izontal position.
3. Remove the six cap screws (12) and washers (11)
from the input cap.
4. Tap shaft with a hammer side to side to loosen the
cap from the housing. Once the cap is loose, pry the
cap out of the housing. Please note that the cap,
cap bearing, seal, shaft and gear will all come out
with the cap.
5. With this cap, shaft and gear assembly removed
from the gearbox, remove retaining ring (22).
6. Remove oil seal (6) from input cap.
7. Support cap and press shaft through the gear. Once
the shaft and gear are separated from the cap, re-
move retaining ring (7) from cap. Cap bearing can
now be removed.
8. Remove input gaskets from the housing face and
cap.
9. Support housing in a vise with the output shaft in a
horizontal position.
10. With the hub/stump jumper/crossbar, castle nut,
cotter pin already removed, remove the four cap
screws (12), lock washers (11) and output cap (16).
11. Remove output gaskets (17) and (18).
12. Push output shaft and pinion (20) down and remove
ball bearing (3), output bearing spacer (10), retain-
ing ring (22), shim (19) and remove output shaft and
pinion (20).
13. 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 pat-
tern is smooth.
14. Inspect vertical and horizontal shafts for grooves,
nicks, or bumps in the areas where the seals seat.
Resurface any damage with emery cloth.
15. Inspect housing and caps for cracks or other
damage.
REASSEMBLE GEARBOX
(Figure 16)
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. Slide ball bearing (3) on to output shaft and pinion
(20). Place against gear and secure with retaining
ring (22).
24 Dealer Service
4. Install shim (19) in output housing bore. Push output
shaft and pinion (20), ball bearing (3) and retaining
ring (22) into housing until ball bearing (3) seats flat
against the shim in housing socket.
5. Insert output bearing spacer (10) and ball bearing
(3) over output shaft until it seats against inside roll-
er bearing (3).
6. Secure output cap (16) with the new output seal
(13) installed to bottom of gearbox housing using
the four 10mm X 1.5 X 25 cap screws (12) and lock
washers (11).
NOTE: Be sure output gaskets (17 and 18) are in
place. Use RTV silicone on gaskets for a leak free
seal. Apply grease to output seal (13) lip for easy
installation.
7. Place ball bearing (21) at back of housing and press
in socket using a round tube of the correct diameter
and a hand press until fully seated.
8. Press new ball bearing (3) into cap (2) socket by
using a round tube of the correct diameter and hand
press until fully seated.
9. Install retaining ring (7) into input cap (2) to retain
the bearing (3).
10. Install retaining ring (23) onto input shaft (4) in the
groove next to the spline. Press shaft (4) through
the bearing (3) that is installed in input cap (2) until
retaining ring is fully seated against bearing (3).
11. Install input gear (23) onto input shaft (4) making
sure it is seated against bearing (3). Install retaining
ring (22) over the spline on input shaft (4) and make
sure it is fully seated against the gear face.
12. Install input shaft, cap, and gear assembly into
housing using one each input gasket (8) and one
each input gasket (9). Using a rubber hammer, tap
the end of the input shaft until the cap face is fully
seated against the gaskets and housing face.
13. Check that the gear backlash is between 0.006"
and 0.016". The backlash can be increased or de-
creased by adding or removing gaskets between the
input cap and housing. Once the backlash is correct
add RTV silicone to the input cap face. Install six
each bolts (12) and six each washers (11) to secure
input cap assembly.
14. Slide input seal (6) onto input shaft (4) and press
into housing flush with front using a tube of correct
diameter. Be careful not to damage seal lip.
15. 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.
16. Remove gearbox from water and dry off with com-
pressed air. With the gearbox placed in the operating
position add SAE 80W of 90W EP oil until it runs
out of back level hole threads. Install level plug and
breather plug (24). Tighten all plugs.
MAN1298
( 08/01/2023 )
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