5
STEP A-6
Squeeze a liberal amount of silicone grease inside the main differential gear.
Locate the side cover plate. Notice that the two alignment notches, in the
side cover plates (arrows) are different sizes. Install the cover plate over the
sun gear shaft and onto the main differential gear. Align the notches. Secure
the side cover plate with four 2.6x8mm countersunk machine screws located
in the machine screw bag.
STEP A-7
Locate the top gear shaft, 9.5mm roll pin, the 22-tooth steel top gear and two
5x8x0.5mm teflon washers. Insert the roll pin, bevelled end first, into the hole
in one end of the top gear shaft. Use a pair of pliers to carefully squeeze the
pin through the shaft until it is centered in the shaft. Be careful not to leave
plier marks, or cause other damage to the top gear shaft.
NOTE: If the top gear and shaft assembly have been pre-assembled for
you at the factory, continue on to step A-9.
STEP A-9
Locate the left and right gearbox halves. Insert a 5x11mm ball bearing into
each of the 4 holes in the gearbox. The ball bearings are located in bag H.
STEP A-10
Slide a 5x8x0.5mm teflon washer over each end of the top gear shaft.
The washers are located in bag H.
STEP A-8
Slide the top gear onto the top gear shaft until the notch in the gear fits over
the roll pin. Make sure that the roll pin does not protrude far enough on
either side to interfere with the gear mesh. Because the top gear press fits
onto the shaft, it may be necessary to place the top gear over the open jaws
of a vise and use a plastic hammer to tap the shaft through the gear. Do not
use a metal hammer for this task, or the shaft may be permanently damaged.
