Subsection 13 (GEARBOX AND 4X4 COUPLING UNIT (WITH EXTERNAL SWITCHES))
Gearbox housing mating surfaces are best
cleaned using a combination of
LOCTITE CHISEL
(GASKET REMOVER) (P/N 413 708 500)
and a brass
brush. Brush a first pass in one direction then
make the final brushing perpendicularly (90°) to
the first pass cross (hatch).
NOTICE
Do not wipe with rags. Use a new
clean hand towel only.
IMPORTANT:
When beginning the application of
the gear housing sealant, the assembly and the
first torquing should be done within 10 minutes.
It is suggested to have all you need on hand to
save time.
Use
LOCTITE 5910 (P/N 293 800 081)
on mating sur-
faces.
Use a plexiglass plate and apply some sealant on
it. Use a soft rubber roller (50 - 75 mm (2 - 3 in)),
available in arts products suppliers for printing,
and roll the sealant to get a thin uniform coat on
the plate (spread as necessary). When ready, ap-
ply the sealant on gear housing mating surfaces.
F
12
R
1
7A
Do not apply in excess as it will spread out inside
gear housing.
NOTE:
It is recommended to apply this specific
sealant as described here to get a uniform appli-
cation without lumps. If you do not use the roller
method, you may use your finger to uniformly dis-
tribute the sealant (using a finger will not affect
the adhesion).
Tighten gear housing screws in a crisscross se-
quence.
TIGHTENING TORQUE
Step A
Hand tightened
Gear housing
screws
Step B
10 N•m ± 1 N•m
(89 lbf•
in
± 9 lbf•
in
)
Install O-ring including distance sleeve on counter-
shaft CVT side.
NOTICE
Place
O-ring
including
distance
sleeve right away. Chamfered bore of distance
sleeve has to face the gearbox.
vmr2006-022-100_a
COUNTERSHAFT END CVT SIDE
1. O-ring
2. Distance sleeve
3. Countershaft end CVT side
Refer to
OUTPUT SHAFT AND COUPLING
MECHANISM
to install these components. Mea-
sure the output shaft backlash.
Installing the Gearbox
The installation is the reverse of the removal pro-
cedure.
Before gearbox installation check O-ring in bearing
cover if brittle, hard or damaged. Replace if nec-
essary.
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