Secondary Gear Bearing Preload
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- Set primary gear into transaxle case. Remove bearing race and adjustment shim from converter housing using Bearing Removing Set (49 W032 2A0), or equivalent. Install plastic funnel and bearing race into transaxle case (if necessary). Place secondary gear and output gear into transaxle case. Install bearing race removed from converter housing onto bearing.
- Mount shim selector gauge from Shim Selector Tool Set (49 B019 0A3) on primary gear and secondary gear and output gear assembly. See Fig 1. Eliminate gap of selector gauge by turning collars "A" or "B" of selector gauge. See Fig 2.
- Mount converter housing on selector gauge. Mount 6 collars between converter housing and bearing housing. Tighten bolts to 14-19 ft. lbs. (19-25 N.m). See Fig 3.
- Turn selector in a direction which widens gap between "A" and "B" of selector gauge until it no longer turns. This will seat bearing race. Turn selector in opposite direction (reducing gap) until gap is eliminated. Insert joint through converter housing
- Mount preload adapter to secondary gear and output gear. See Fig 4. Measure preload (turning torque) with torque wrench. Widen gap on selector gauge to obtain 13-21 INCH lbs. (1.5-2.4 N.m) reading.
- Measure clearance between "A" and "B" of selector gauge when specified preload is obtained. Measure clearance around entire circumference and select a shim equal to maximum clearance measured. The maximum allowable number of adjustment shim is one. Take the maximum reading and determine the shim to be used. Shims range in thickness of 0.020-0.051" (0.50-1.30 mm) in increments of 0.002" (0.05 mm).
- Remove converter housing and selector gauge. Install required shim(s), press bearing race into converter housing and install onto transaxle housing. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Check secondary gear and output gear bearing preload (turning torque). Preload should be 13-21 INCH lbs. (1.5-2.4 N.m).