Disassembly and Assembly

DISASSEMBLY

Fig. 4:

1. Remove drain plug and drain fluid (Fig. 4).

Fig. 5:

2. Remove flex plate bolts (Fig. 5).

Fig. 6:

3. Remove flex plate and backing plate (Fig. 6).

Fig. 7:

4. Remove drive flange nut. Use a deep 1 1/4 inch socket (Fig. 7).

Fig. 8:

5. Remove drive flange (Fig. 8).

Fig. 9:

6. Remove front bearing seal (Fig. 9).

Fig. 10:

7. Remove rear seal (Fig. 10).

Fig. 11:

8. Install Special Tool # C-293-1 base into shop press (Fig. 11).

Fig. 12:

9. Position bell housing into shop press (Fig. 12).
10. While holding onto bottom of shaft, press out shaft from bell housing.
11. Remove outer bearing from housing.

NOTE: Replace crush sleeve whenever disassembling bell housing.

12. Remove crush sleeve from shaft.
13. Install Special Tool # P-334 splitter onto shaft.

Fig. 13:

14. Install shaft into shop press (Fig. 13)
15. Remove bearing from shaft.

Fig. 14:

16. Remove outer bearing cup from housing using Special Tool # D-4345 remover, C-4171 driver, and C-4171-2 extension (Fig. 14).

Fig. 15:

17. Remove inner bearing cup from housing using Special Tool # D-158 remover, C-4171 driver, and C-4171--2 extension (Fig. 15).

ASSEMBLY

Fig. 16:

1. Install inner bearing cup to housing using Special Tool # D-146 installer, and C-4171 driver (Fig. 16).

Fig. 17:

2. Install outer bearing cup using Special Tool # D-142 installer, and C-4171 driver (Fig. 17).

Fig. 18:

3. Install new inner bearing to shaft using Special Tool # CT-1075 adapter, and MD998805 driver. Press on new bearing in shop press (Fig. 18).
4. Install new crush sleeve.
5. Lightly lubricate bearing and install shaft into housing.
6. Lightly lubricate and install outer bearing onto shaft in housing.
7. Position flange onto shaft and align shaft splines to flange.

Fig. 19:

8. Lightly tap bearing into position using flange (Fig. 19).
9. Tap on flange to position and seat outer bearing.
10. Remove flange.
11. Install new outer seal using Special Tool # C-4698-2.

Fig. 20:

12. Install flange, install the washer and a new nut on the shaft. Tighten flange nut using Special Tool # 6958 holder (Fig. 20). Use a deep 1 1/4 inch socket.
13. Tighten the nut to 298 Nm (220 ft. lbs.) minimum. Do not over-tighten. Maximum torque is 380 Nm (280 ft. lbs.).

CAUTION: Never loosen shaft nut to decrease shaft bearing rotating torque and never exceed specified preload torque. If preload torque is exceeded a new collapsible spacer must be installed. The torque sequence will have to be repeated.

NOTE: A new collapsible spacer will start to crush at around 265 ft. lbs. torque. If the spacer requires more than 280 ft. lbs. torque to crush, the collapsible spacer is defective.

14. Using yoke holder 6958, a short length of 1 inch pipe, and a torque wrench set at 380 Nm (280 ft. lbs.), crush collapsible spacer until bearing end play is taken up.
15. Slowly tighten the nut in 6.8 Nm (5 ft. lbs.) increments until the rotating torque is achieved. Measure the rotating torque frequently to avoid over crushing the collapsible spacer.
16. Check rotating torque with an inch pound torque wrench. The torque necessary to rotate the shaft should be 0.56 Nm to 1.65 Nm (5 to 15 in. lbs.).

Fig. 21:

Fig. 22:

17. Install new seal at flex plate end using Special Tool # 6926-1 guide, and 6926-2 installer (Fig. 21) (Fig. 22).
18. Install flex plate and backing plate.
19. Install drain plug.