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10
12. Install thrust plate (41) onto the shaft, and the dowel pin (50) into the shaft as shown (Figure 10-43).
13. Install the spur (governor drive) gear (40) onto the shaft with either side down. Mate the notch in the
gear with the dowel pin as shown (Figure 10-43, Page 53).
14. Install the spring (Belleville) washer (39) onto shaft with the raised center toward the end of the shaft.
15. Press a new bearing (38) onto the end of the shaft until it seats (Figure 10-43). Make sure that the
input gears turn freely.
SHIFTER FORK ASSEMBLY
1. Install the spring (35) and ball (36) into the shift fork (34) as shown (Figure 10-43, Page 53).
2. Use a very small phillips-head screwdriver to depress the ball and spring while inserting shift rod (33)
into the shift fork. Remove screwdriver when the shift rod is inserted far enough for it to depress the ball
and spring, then continue to insert rod until the ball is positioned in the middle detent on the rod.
DIFFERENTIAL GEAR CASE ASSEMBLY
1. If the bearings (79) were removed, press new ones onto the differential gear carrier case (84) and car-
rier case cover (87) (Figure 10-6, Page 39).
2. Install differential gear (91) into the carrier case (84) (Figure 10-6, Page 39) as shown (Figure 10-62).
3. Start the differential pin (88) (Figure 10-6) into the carrier case by lightly tapping it in with a hammer as
shown. Before the pin enters the inside of the carrier case, position the thrust plate (85) and idler gear
(89) (Figure 10-6, Page 39) in the case and then continue tapping the pin through the thrust plate and
idler gear as shown (Figure 10-63).
• APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY. APPLYING PRES-
SURE ANYWHERE ELSE WILL DAMAGE THE BEARING.
• APPLY PRESSURE AGAINST THE INNER RACE OF THE BEARING ONLY. APPLYING PRES-
SURE ANYWHERE ELSE WILL DAMAGE THE BEARING.
FIGURE 10-62
FIGURE 10-63
CAUTION
CAUTION
DIFFERENTIAL
GEAR CARRIER
CASE
INSERT
DIFFERENTIAL
GEAR INTO
DIFFERENTIAL
GEAR CARRIER
CASE
POSTION IDLER
GEAR AND
THRUST PLATE
IN CARRIER
CASE ...
...THEN TAP DIFFERENTIAL PIN INTO CARRIER CASE,
THROUGH THRUST PLATE AND IDLER GEAR, THEN
CONTINUE TO TAP DIFFERENTIAL PIN ABOUT
ANOTHER INCH PAST IDLER GEAR
Summary of Contents for 1997 DS
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