Final assembly

1. Install the lower gear along with the calculated number of shims.

2. Install the washer (1), the locking ring (2), the spring (3) and the engagement sleeve (4) onto the shaft (5).

NOTE! The end of the engagement sleeve marked ‘TOP’ must be facing upwards on the shaft. On earlier models there is a drilled recess, which must be turned upwards. The engagement sleeve must rest lightly on the spring. Feel by hand to make certain.

3. Install the needle bearings (1) and the spacer ring (2, model 290A only) between the bearings in the lower gear and insert the shaft in the gear. NOTE! The needle bearings are matched in pairs and must not be mixed up.

5. Place the upper gear wheel with the calculated shims in the gear housing. Install the needle bearings (1) along with the spacer ring (2, model 290A only) between the bearings.

4. Install the brass washer and the split locking ring. Then place the gear housing in the splines sleeve 884830

NOTE! Carefully inspect the condition of the brass washer and replace if necessary.

6. In order to obtain the correct axial clearance, there are three left hand threaded nuts with shoulders of different thicknesses (1). Select a nut and tighten it with a tightening torque of 120 Nm (88.3 lb.ft.)

NOTE! Lubricate the threads to prevent the nut from galling.

7. Measure the clearance between the nut and the bearing. The axial clearance should be 0.1–0.5 mm, 0.00394–0.0197"). If it should not be possible to obtain the correct clearance with any of the nuts, most probably the bearing is defective.

9. Coat the surfaces between the double bearing box and the gear housing with sealing compound, Volvo Penta part no. 1161099-5 or Permatex® no. 3. Install the double bearing box with the universal joint in the gear housing.

Coat the screws with thread locking compound, Volvo Penta part no. 1161053-2 or Loctite® 243 and tighten them with a torque of 35 Nm (25.8 lb.ft.)

10. Install a sufficient number of shims underneath the cover to obtain a clearance of max 0.1 mm (0.004") between the cover and the gear housing. Locate the cover and push it lightly into position and measure the clearance all around with a feeler gauge.

11. Coat the cover with sealant, Volvo Penta part no. 1141570-0 and install the sealing ring (1) so that the sealing for the front, right hand screw ends up in the recess of the cover, provided for it.

12. Insert the calculated shims and tighten the cover. NOTE! The front, right hand screw is a hollow screw, to be installed with an O-ring underneath the head of the screw. Tighten the screws with a torque of 15 Nm (11.04 lb.ft.) in diagonal sequence.