5-101.bk Page 12 Friday, March 17, 2006 11:05 AM [212 HV] Crankshaft Gear INSPECTION Take care not to damage gear teeth while seating gear. 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. 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. REPLACEMENT Refer to Figure 5-9. 1.
Using a suitable puller such as J 21834-4A, remove gear and key. 4 1 2 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. 3 Take care not to damage key slot while installing key. 6 5 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. Figure 5-9 — Drive Gear Installation 200338a Wear protective gloves when handling heated crankshaft gear to prevent burns or personal injury. Page 5-12 200 BENCH PROCEDURES 1.
Gear 2. Shaft 3. Key slot 4. Key 5. Flange 6. Chamfer