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> There sure are a lot of parts in a 901 box, Now I'm going to try to put them back in
DNHunt
post Nov 5 2005, 09:40 PM
Post #41


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The finished pinion shaft assembly


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bd1308
post Nov 5 2005, 09:52 PM
Post #42


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wow. so 2nd and 3rd are the only gears with a slider...?

1st and reverse is on the other side of the intermediate plate right?

b
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DNHunt
post Nov 6 2005, 06:12 AM
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Time to assemble the drive shaft. 2nd gear on the usual box is ground as part of the drive shaft so, so I got a freebie cause there is no way to screw it up. The first thing I put on was the race for the double ball bearing in the intermediate plate. It goes on the side of 2nd gear with the short part of the shaft.


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DNHunt
post Nov 6 2005, 06:14 AM
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Now I turned the shaft over so i was putting parts on the long end of the drive shaft. 3rd gear next


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DNHunt
post Nov 6 2005, 06:15 AM
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Next goes a flat washer


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DNHunt
post Nov 6 2005, 06:20 AM
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Here's the beginning of the one mistake I made (the one I caught at least). Next goes the 4th gear assembly. It goes on over a race and roller bearing just like 2nd and 3rd assemblies on the pinion shaft. Always, dogteeth toward the slider


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DNHunt
post Nov 6 2005, 06:23 AM
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4th, 5th slider hub. There is no right or wrong side, just slide it on.


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DNHunt
post Nov 6 2005, 06:31 AM
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4th, 5th slider. I swapped this slider with the 2nd, 3rd slider because the 2nd, 3rd slider had a touch of wear and 4th and 5th don't get used as much as 2nd and 3rd.


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DNHunt
post Nov 6 2005, 06:33 AM
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I'm still continuing in my ignorance. 5th gear assembly goes on with the dogteeth down toward the slider.


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DNHunt
post Nov 6 2005, 06:34 AM
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Cone washer


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DNHunt
post Nov 6 2005, 06:37 AM
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Next goes the smaller roller bearing and a locking plate. The tab goes in the slot pointed down to go under the bearing.


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DNHunt
post Nov 6 2005, 06:40 AM
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Tighten the nut down to 80 lbs and bend up 1 edge of the locking plate and the drive shaft is ready. I still haven't caught my mistake. Anyone that has been in one of these boxes should see it now.


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sj914
post Nov 6 2005, 06:46 AM
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4th and 5th gear are in the wrong order?
How did you torque that nut to 80ft/lbs.?
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DNHunt
post Nov 6 2005, 07:01 AM
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You are RiIGHT. It won't go in the intermediate plate like that. I guessed. I did mark the shaft and nut so I got them to the same spot.
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DNHunt
post Nov 6 2005, 07:03 AM
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Ah, the intermediate plate. I installed the bearing races (the whole bearing for the pinion shaft).


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DNHunt
post Nov 6 2005, 07:05 AM
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Next comes the spacer that goes under the bearing retainer plate.


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DNHunt
post Nov 6 2005, 07:06 AM
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The bearing retainer plate


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DNHunt
post Nov 6 2005, 07:07 AM
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Here is another use for the CV joint tool. 8mm 12point.


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DNHunt
post Nov 6 2005, 07:08 AM
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Torqued to 15-17 lb ft. I had a heck of a time figuring out how to steady the intermediate plate while I torqued it. I finally put a couple of 8mm bolts in my vice and put the plate over them.


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DNHunt
post Nov 6 2005, 07:15 AM
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I'm ready to drive the race down the pinion shaft


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