Usage:
The marine gear top shaft and planetary gear section, including the drive shaft and sun gear, must be removed before the bottom gear shaft assembly can be removed.
The following lower shaft removal illustrations show the marine gear removed from the engine, with the bottom cover removed, and the gear housing turned with the bottom up.
NOTE: If it is necessary to remove the bottom shaft and the marine gear cannot be disconnected from the engine see the topic, BOTTOM SHAFT REMOVAL AND INSTALLATION-ALTERNATE METHOD.
1. Remove front and rear pan assemblies (1).
BOTTOM COVER REMOVED FROM HOUSING
1. Front and rear pan assemblies.
BOTTOM SHAFT
2. Bottom shaft and gear assembly. 3. Bearing rear retainer bolt (eight). 4. Bearing cap bolts (six).
2. Loosen the eight bearing rear retainer bolts (3). Remove the six bearing cap bolts (4) and the bearing caps.
3. Lift the bottom shaft gear assembly out of the housing.
BOTTOM SHAFT REMOVED
Bottom Shaft Installation
1. Install the bottom gear shaft assembly in position in the marine gear housing. Tighten the six bearing cap bolts (4) only enough to seat the shaft bearings in the housing.
2. Tighten the eight bearing rear retainer bolts (3), then finish tightening the bearing cap bolts (4).
3. Install the drive shaft and sun gear, the planetary gear section, the top shaft, the covers and components which were removed.
Bottom Shaft Removal and Installation-Alternate Method
NOTE: If the bottom shaft is to be removed and installed with the marine gear connected to the engine, it is necessary to make a heat treated stepped key. See the topic, BOTTOM SHAFT INSTALLATION-ALTERNATE METHOD for the type of steel, the machining dimensions and the specific hardness of the stepped key.
Bottom Shaft Removal-Alternate Method
The tools illustrated are used when removing the bottom shaft without disconnecting the marine gear from the engine.
BOTTOM SHAFT REMOVAL TOOLS
1. 5H9817 Hydraulic Puller. 2. FT1008 Bracket-Puller. 3. FT1004 Plate-Removal. 4. FT1009 Bar-Power, 1B4210 Nuts (two). 9S5800 Pump Group now shown.
FT1008 BRACKET-PULLER
Dimensions in inches (mm)
FT1004 PLATE-REMOVAL
Dimensions in inches (mm)
FT1007 BAR-POWER, AND NUTS
Dimensions in inches (mm)
The marine gear top shaft, planetary gear section, the sun gear shaft and the idler gear are removed from the marine gear housing before the bottom shaft is removed.
1. Remove the bolts, locks and gear retainer from the front of the bottom shaft.
2. Attach FT1008 Bracket (2) to the gear housing.
3. Assemble FT1007 Bar, 1B4210 Nuts, FT1004 Plate and 5H9817 Hydraulic Puller through the bottom shaft.
BOTTON SHAFT REMOVAL
1. 5H9817 Hydraulic Puller. 2. FT1008 Bracket. 4. FT1009 Bar and 1B4210 Nuts. 5. Bottom shaft rear bearing.
4. The bottom shaft and rear bearing (5) are removed as a unit.
NOTE: Place slings around the bottom shaft gear hubs to prevent the gears from dropping into the pan assemblies when the shaft is removed from the marine gear housing.
5. Separate bearing (5) from the bottom shaft, after the shaft and bearing have been removed, by using either a press or bearing pulling tools.
Bottom Shaft Installation-Alternate Method
The tools illustrated are used when installing the bottom shaft into the gears and bearings, in the marine gear housing. A hardened stepped key is used in the bottom shaft and rear gear when the shaft is installed. See the dimensional drawing for the correct size and specific hardness of the FT1009 Key.
FT1009 KEY-STEPPED
Dimensions in inches (mm)
BOTTOM SHAFT INSTALLATION TOOLS
1. 5H9817 Hydraulic Puller. 2. FT1008 Bracket-Puller. 4. FT1007 Bar-Power, 1B4210 Nuts. 6. FT1005 Plate (front). 7. FT1006 Plate (rear). 9S5800 Pump Group not shown.
FT1005 PLATE (FRONT)
Dimensions in inches (mm)
1. The slings around the gear hubs should be positioned to align the gear bores with the bearing bore in the marine gear.
FT1006 PLATE (REAR)
Dimensions in inches (mm)
NOTE: The stepped key and the straight key must slide freely in the bottom shaft and the corresponding gear before the shaft installation begins.
2. Insert the stepped key in the shaft large diameter keyway with the step as far forward on the shaft as possible. The bearing spacer will slide the key back into position in the gear as the shaft is installed.
3. Carefully push the shaft by hand, through the back gear, the bearing spacer and the bearing until the chamfer on the shaft bearing diameter rests in the bearing in the housing.
4. Slide the front gear key halfway in the shaft keyway and halfway in the gear key slot. The key will slide into position in the gear as the shaft is installed.
5. Assemble hydraulic puller (1), bar and nuts (4) plates (6 and 7) through the bottom shaft. The small pilot diameter of plate (6) is used in the bore of the front gear to support the end of bar (4). Bracket (2) is used to support the other end of bar (4).
6. Initially press the bottom shaft approximately 1/4 in. (6,3 mm) into the front gear. Remove the front bar nut and plate (6) and check the key position. THE KEY MUST BE IN CORRECT ALIGNMENT BEFORE PROCEEDING WITH THE SHAFT INSTALLATION.
7. When the key is aligned in the shaft and front gear, install plate (6) and the nut on the bar. Continue forcing the shaft into the gears and bearing until the shaft is almost installed, then remove the bar and hydraulic puller assembly.
8. Place bottom shaft rear bearing (5) in position on the bottom shaft. Assemble hydraulic puller (1), bar and nuts (4) and plates (6 and 7) through bearing (5) and the bottom shaft.
BOTTOM SHAFT INSTALLED
1. 5H9817 Hydraulic puller. 2. FT1008 Bracket. 4. FT1007 Bar and 1B4210 Nuts. 6. FT1005 Plate. 7. FT1006 Plate.
If the pilot diameter of plate (6) is in the bore of the front gear the bottom shaft cannot be forced into the correct location in the gears and bearings. The FLAT FACE of plate (6) must be against the front gear hub for final shaft installation.
9. Remove the installation tools and install the front gear retainer, bolts and locks and the shaft rear bearing retainer, bolts and locks.
10. See the covering topics to install the idler gear, the sun gear drive shaft, the top shaft, the planetary gear section, the oil manifold and filter assembly, the hydraulic pump and the marine gear top cover.
Bottom Shaft Disassembly
- 1H3107 Push Puller.1H3109 Leg (two).1H3110 Bearing Pulling Attachment.5F7343 Bearing Pulling Attachment.5H9817 Hydraulic Puller.3S6224 Electric Hydraulic Pump or9S5800 Pump Group.
FRONT GEAR REMOVAL
1. Round bar or thick walled tube approximately 43/8" (110 mm) diameter and 4" (101 mm) long.
REAR BEARING AND GEAR REMOVAL
1. Round bar or thick walled tube approximately 43/8" (110 mm) diameter and 4" (101 mm) long.
1. To remove the front gear from the shaft, remove the six gear retainer bolts, three locks and the retainer ring. Tools used to force the gear from the shaft are: 1H3110 Bearing Pulling Attachment, 1H3109 Legs, 1H3107 Push Puller, 5H9817 Hydraulic Puller and either a round bar or thick wall tubing (1) with approximately 4 3/8" (110 mm) diameter and 4" (101 mm) length.
2. To remove the shaft rear bearing and gear, remove the six bearing retainer bolts, three locks and the bearing retainer ring. Use the same tools which were used to remove the front gear. Remove the gear key from the shaft.
BEARING ASSEMBLY REMOVAL
2. Bearing assembly. 3. Spacer.
3. Bearing assembly (2) and spacer (3) are removed at the same time. Place the 5F7343 Bearing Pulling Attachment under spacer (3). Assemble the 1H3109 Legs, 1H3107 Push Puller, the 5H9817 Hydraulic Puller and remove the bearing assembly.
Bottom Shaft Assembly
Bearing assembly (2) cones and cups are numbered. Keep the cone and cup with corresponding numbers together when installing the bearing assembly.
Heat the bearings and gears in oil, temperature not to exceed 175° F (135° C), to facilitate installation.
1. Place spacer (3) on the shaft. Install the first bearing cone with the small diameter toward the spacer. Install the other bearing cone with the large diameter against the large diameter of the installed bearing cone.
2. Place the cup, with the number corresponding to the last cone installed, on the cone.
3. Place the gear key in the shaft and install the rear gear.
4. Install the rear roller bearing, the bearing retainer, three locks and six bearing retainer bolts.
5. Place the bearing cup spacer and the last bearing cup on the shaft, which completes the installation of bearing assembly (2).
6. Install the front gear, the gear retainer, three locks, six gear retainer bolts. The shaft is assembled, ready for installation in the housing.