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Repair instructions
Shimming the upper gear to the
intermediate housing
1. Measure the distance from the bottom of the upper
gear housing to the top of the outer bearing race (A).
Record the measurements in the table below.
NOTE! The shift mechanism must be in neutral (if in-
stalled) to achieve and accurate measurement.
2. Measure the distance from the top of the intermedi-
ate housing and the upper gear head lower bearing
outer race seat. (B). Record the measurement in the
table below.
Bmm
- A mm
Clearance mm
+ 0.06 mm
Shims Required mm
3. Subtract the upper gear head bearing thickness (A,
figure under point 1) from the intermediate housing
measurement to find the bearing clearance. Add
enough shims to take up the clearance plus 0.06 mm
shim to preload the upper gear head bearing.
Apply a light coating of Volvo Penta part no. 1141570
sealant to the mating surfaces of the intermediate
housing and the upper gear head. Install the upper
gear head on the intermediate housing with the calcu-
lated shims in place.
4. Install the splines sleeve (1) on the vertical drive
shaft and the O-ring (2) plus the shims calculated
under point 2 (3) on the intermediate housing.
Check to make sure that the O-ring (4) for the spacer
sleeve is properly in its location. The contact surfaces
have to be coated with sealing compound, Volvo
Penta part no. 1161099-5 or Permatex
®
no. 3.
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