Idler Gear: Service and Repair

DISASSEMBLY
1. Use Torque Adapter T87C-77000-E to secure the idler gear in a vise.

CAUTION: Use protective plates to prevent damage to the special tool.





2. Use Main shaft Lock nut Wrench T88T-7025-AR along with a 1-5/8 inch socket to remove the shaft nut.
3. Remove the idler gear bearing.
4. Remove the spacer.
5. Remove the idler gear from the idler gear shaft.
6. Remove the shim.
7. Remove the other idler gear bearing.





8. Use Internal Pull D80L-943-A or equivalent and Impact Slide Hammer T50T-100-A and remove the one bearing cup from the idler gear.





9. Use Step Plate Adapter D80L-630-11 (part of D80L-630-A) or equivalent to press out the other bearing cup.





ASSEMBLY
1. Use Pinion Bearing Cup Replace T80T-4000-E to press the bearing cups into the idler gear.
2. Install the idler gear bearing on the Idler gear shaft.
3. Install the shim.
4. Install the spacer.
5. Install the idler gear.
6. Install the other idler gear bearing.





7. Use Torque Adapter T87C-77000-E to secure the idler gear in the vise.

CAUTION: Use protective plates to prevent damage to the special tool.





8. Use Main shaft Lock nut Wrench T88T-7025-AR along with a 1-5/8 inch socket and tighten the shaft nut to 128-176 Nm (95-130 ft. lbs.).
9. Turn the idler gear and adapter over and secure the idler gear in a vise.

CAUTION: Use protective plates to prevent damage to the idler gear.





10. Attach a torque wrench to Torque Adapter T87C-77000-E, and measure while tightening the shaft nut to 128-176 Nm (95-130 ft. lbs.). The pre load should be 0.03-0.88 Nm (0.3-7 inch lbs.).

NOTE: Read the preload when the idler gear shaft starts to turn.

11. If the specified preload is not reached within the specified tightening torque select an appropriate shim.

NOTE:
^ The pre load can be reduced by increasing the thickness of the shims. DO NOT use more than seven shims.
^ Select an appropriate adjustment shim from one of the following kits:
^ F32Z-7N112-A for thickness between 4.540-4.995 mm (0.1787-0.1966 inch) in increments of 0.035 mm (0.0013 inch)
^ F32Z-7N112-B for thickness between 5.030-5.310 mm (0.1980-0.2090 inch) in increments of 0.035 mm (0.0013 inch).