User Manual

Page 5-12
200 BENCH PROCEDURES
[212 HV] Crankshaft Gear
INSPECTION
After inspecting the crankshaft and determining
that it is serviceable, inspect crankshaft gear for
cracks and broken, worn or chipped teeth. If
crankshaft gear is defective, it must be replaced.
REPLACEMENT
Refer to Figure 5-9.
1. Using a suitable puller such as J 21834-4A,
remove gear and key.
The threads in the end of the crankshaft are
M8 x 1.25.
2. Clean gear mounting surface. It should be
free of grooves, scratches and burrs. Use a
file, sandpaper or crocus cloth, as required.
Take care not to damage key slot while installing
key.
3. Insert key (4) into key slot (3). Lightly tap key
into slot with a soft metal hammer.
4. Heat replacement gear (1) to approximately
250°F (121°C) in a temperature-controlled
oven or on a hot plate.
Wear protective gloves when handling heated
crankshaft gear to prevent burns or personal
injury.
Take care not to damage gear teeth while seating
gear.
5. Position the gear over end of shaft (2) with
timing mark outward, chamfer (6) toward
rear of the shaft, and key slot aligned with
key in shaft. In one rapid motion, push
heated gear against flange (5). When gear is
in place, immediately and carefully tap on
gear to help seat it against flange.
Figure 5-9 — Drive Gear Installation
1. Gear
2. Shaft
3. Key slot
4. Key
5. Flange
6. Chamfer
200338
a
1
2
6
3
5
4
5-101.bk Page 12 Friday, March 17, 2006 11:05 AM