Output Shaft Repair
NOTE: Transfer shaft should be removed for repair of output shaft. Planetary gear sets must be removed to accurately check output shaft bearing turning torque.Remove Output Shaft Retaining Nut And Washer:

Remove Output Shaft Gear:

Output Shaft Gear And (Select) Shim:

Remove Output Shaft Gear Bearing Cone:

Install Output Shaft Gear Bearing Cone:

Remove Output Shaft And Rear Annulus Gear Assembly:

Remove Output Shaft:

Remove Rear Planetary Annulus Gear Bearing Cone:

Install Rear Planetary Annulus Gear Bearing Cone:

Install Output Shaft Into Rear Planetary Annulus Gear:

Remove Output Shaft Gear Bearing Cup:

Remove Rear Planetary Annulus Gear Bearing Cup:

Install Output Shaft Gear Bearing Cup:

Install Rear Planetary Annulus Gear Bearing Cup:

DETERMINING SHIM THICKNESS
Shim thickness need only be determined if any of the following parts are replaced:
- Transaxle case
- Output shaft
- Rear planetary annulus gear
- Output shaft gear
- Rear annulus and output shaft gear bearing cones
- Overrunning clutch race cups.
Refer to Bearing Adjustment Procedure, to determine proper shim thickness. Check output shaft bearings turning torque, using an inch-pound torque wrench. If turning torque is 3 to 8 inch-pounds, the proper shim has been installed.
Install Output Shaft Assembly:

Output Shaft And (Select) Shims In Position:

Start Output Shaft Gear Onto Output Shaft:

Holding Output Shaft Gear:

Tighten Output Shaft Retaining Nut To 271 Nm (200 Ft. Lbs.):

Checking Output Shaft End Play:

Checking Bearings Turning Torque:
