D SERIES
OM-01516
MAINTENANCE & REPAIR
PAGE E - 12
maining hardware (37, 38, 39, 41, 42, 43, 44, 45, 48
and 49).
NOTE
The shoulder bolts and capscrews securing the
gearbox cover to the gearbox housing are of differ
ent lengths. For ease of reassembly, record the po
sitions of the shoulder bolts and capscrews at the
time of removal.
Remove the gear housing gasket and clean all the
mating surfaces.
NOTE
If the gear cover does not readily separate from the
housing, remove the hardware (10 and 11), install a
5/8‐11 UNC by 4‐inch long capscrew, and jack the
cover from the housing. Remove the jacking screw
and replace the hardware (10 and 11).
After the gear cover has been removed, inspect the
pinion shaft bushing (13). If replacement is re
quired, remove the cover plug (14) and press the
pinion shaft bushing (13) from the cover bore. Slide
the pinion shaft washer (12) off the pinion shaft (28)
and tag it for reference during reassembly.
Use a bearing puller to remove the crankshaft
bearing (9) from the crankshaft (35). Remove the
spacer (31).
Install two 5/8‐11 UNC capscrews in the tapped
holes in the crankshaft gear (3), and use a gear
puller to slide the gear off the crankshaft. Retain the
crankshaft gear key (8). Remove the capscrews
from the gear.
Remove the snap ring (36) and slide the crankshaft
and crankshaft bearing (2) out of the gearbox
housing.
To disassemble the pinion shaft and components,
slide the shaft and assembled pinion gear (27) out
of the shaft bushing (30). The pinion gear is re
tained on the shaft by tight friction fit and does not
normally require removal. If removal is required,
press the pinion gear from the shaft.
Inspect the pinion shaft bushing and, if replace
ment is required, remove the plug (29) and press
the bushing from the gear housing bore.
After removing the shafts and bearings, clean and
inspect the bearings
in place
as follows.
To prevent damage during removal from
the shaft, it is recommended that bearings
be cleaned and inspected
in place
. It is
strongly
recommended that the bearings
be replaced
any
time the shaft and bear
ings are removed.
Clean the gear housing, shaft and all component
parts (except the bearings) with a soft cloth soaked
in cleaning solvent. Inspect the parts for wear or
damage and replace as necessary.
Most cleaning solvents are toxic and flam
mable. Use them only in a well ventilated area
free from excessive heat, sparks, and flame.
Read and follow all precautions printed on sol
vent containers.
Clean the bearings thoroughly in
fresh
cleaning
solvent. Dry the bearings with filtered compressed
air and coat with light oil.
Bearings must be kept free of all dirt and
foreign material. Failure to do so will great
ly shorten bearing life.
Do not
spin dry
bearings. This may scratch the balls or
races and cause premature bearing fail
ure.
Rotate the bearings by hand to check for rough
ness or binding and inspect the bearing balls. If ro
tation is rough or the bearing balls are discolored,
replace the bearings.
The bearing tolerances provide a tight press fit
onto the shafts and a snug slip fit into the gear
housing. Replace the bearings, shafts, eccentric
housing, or gear housing if the proper bearing fit is
not achieved.
