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CHANGING INPUT SHAFT

Special Procedure

In some cases, it may become necessary to replace the input shaft due to excessive clutch wear on the splines. Except for removal of the shift bar housing assembly, the input shaft can be removed without further disas- sembly of the transmission. Removal of the clutch housing is optional.

NOTE: The following illustration and instructions pertain to changing the input shaft ONLY. To change the main drive gear, disassembly of the front section is required.

Disassembly

  • 1.

    Remove the gear shift lever housing assembly (or remote control assembly) from shift bar housing, if necessary, and the shift bar housing assembly from transmission case.

  • 2.

    Remove the front bearing cover and gasket. If nec- essary, remove the oil seal from cover of models so equipped.

  • 3.

    Remove the drive gear bearing nut (left hand threads) or snap ring from input shaft. Suggestion: For removal of nut ONLY, engage Iwo mainshaft sliding clutches into gear to prevent the mainshaft from rotating.

  • 4.

    Move the main drive gear assembly as far forward as possible and remove the drive gear bearing.

  • 5.

    Remove the spacer from input shaft.

  • 6.

    From the front of transmission, remove the snap ring from I.D. of main drive gear using two small screwdrivers. If mainshaft was previously locked in two gears, it may become necessary to place sliding clutches in the neutral position to rotate input shaft for removal of snap ring.

  • 7.

    Pull the input shaft forward and from splines of drive gear.

Reassembly

  • 1.

    If necessary, install bushing in pocket of input shaft.

  • 2.

    Install new input shaft into splines of main drive gear just far enough to expose snap ring groove in I.D. of drive gear.

  • 3.

    Install snap ring in groove of drive gear.

  • 4.

    install spacer on input shaft.

  • 5.

    Using a flanged-end driver, install the drive gear bearing on shaft and into case bore. When apply- ing force to driver, use caution so as not to dam- age bearing shield. Suggestion: Engaging the sliding clutch into main drive gear and blocking it forward will hold the input shaft forward.

  • 6.

    When drive gear bearing nut is used, degrease the threads of input shaft and new nut. DO NOT REUSE OLD NUT. When snap ring is used, install the snap ring in groove of input shaft and pro- ceed to #10.

  • 7.

    Apply Fuller Transmission adhesive sealant #71204 or equivalent to the cleaned threads of in- put shaft and nut, using caution so as not to con- taminate bearing with sealant.

  • 8.

    Engage two mainshaft sliding clutches into gear to prevent the mainshaft from rotating and install the new drive gear bearing nut, left-hand threads, on input shaft. Tighten nut with 250-300 Lbs./Ft. of torque.

Suggestion: To avoid damaging the O.D. of nut, use the tool specifically designed for this pur- pose. See TOOL REFERENCE.

  • 9.

    With a punch and maul, peen the nut into the two milled slots of input shaft, using caution so as not to distort O.D. of nut.

  • 10.

    To facilitate proper reinstallation of the shift bar housing assembly on case, make sure mainshaft sliding-clutches are placed in the neutral posi- tion.

  • 11.

    Reinstall the shift bar housing assembly, the front bearing cover and all other parts and as- semblies previously removed, making sure to re- place the gaskets used.

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