Yanmar 1GM10, Shop Manual

Page: 226 / 240

CHAPTER ELEVEN
Input shaft
1. Check the gear teeth for excessive wear, corrosion or
rust and mechanical damage. Check the teeth for galling,
chips, cracks, missing pieces, distortion or discoloration
from overheating. Replace the input shaft if the gears are
damaged.
2. Inspect the input shaft bearings and seal surfaces for
excessive wear, grooves, metal transfer and discoloration
from overheating. Use a press to remove damaged bear-
ings and to install new bearings.
NOTE
Shims (39, Figure 3) behind the outer bear-
ing race in the mounting flange determine
bearingpreload for the input shaft bearings.
Save the shims and reinstall them
the original parts.
3. Inspect the input shaft bearing outer races in the trans-
mission case and mounting flange. If either race is dam-
aged or excessively worn, remove it using a suitable
puller.
Intermediate shaft
1. Remove and discard the O-ring (46, Figure 3) at the
end of the shaft.
2. Remove the thrust washer (47, Figure 3), idle gear
(45) and roller bearings (44).
3. Inspect the bearings, shaft and reverse idler gear inside
diameter for excessive wear, grooves, metal transfer and
discoloration from overheating. If necessary, replace the
shaft, gear and bearings.
4. Check the idler gear teeth for excessive wear, corro-
sion or rust and mechanical damage. Check the teeth for
galling, chips, cracks, missing pieces, distortion or discol-
oration from overheating. If necessary, replace the gear.
5. Reassemble the intermediate shaft. Install a new
O-ring on the shaft. Check that the idler rotates
on
the shaft.
Output shaft
NOTE
Exercise care when using the puller in Step
1. Make sure the threads on the output shaft
are not damaged.
1. Using a suitable puller, remove the output shaft from
the forward and reverse gear assemblies as shown in
Fig-
ure 4. Do not mix the forward gear parts and reverse gear
parts.
2. Remove the spacer (9, Figure 3) and the bearing inner
race (7) from the output shaft.
3.
Hold the threaded end of the output shaft so the threads
are protected.
4. Place the outer race onto the front bearing inner race.
Using a suitable bearing driver, gently drive the inner
bearing race away from the shaft collar approximately 10
mm.
5.
Place a pulling support plate (such as Yanmar special
tool 17099-09030) between the collar of the output shaft
and bearing.
6. Use Yanmar special tool 17095-09070, or a suitable
equivalent tool, to press the bearing off the shaft, as shown
in
Figure 5.
7. Remove the clutch friction plates (14, Figure 3) and
steel plates (15) from the forward gear (10).
8. Use Yanmar special tool 17095-09070, or an equiva-
lent tool, to compress the Belleville springs
Figure 3)
and remove the snap ring from the forward gear, as shown
in
Figure 6.