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 installed) to achieve and accurate measurement.

Shims Requiredmm

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 calculated shims in place.

2. Measure the distance from the top of the intermediate housing and the upper gear head lower bearing outer race seat. (B). Record the measurement in the table below.

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.

6. Install the upper gear housing on the intermediate housing. Use new Allen bolts (1, 2 pcs), washers (2, 2 pcs) and nyloc nuts (3). Many drives do not have washers under the bolt heads. When overhauling however, washers shall always be fitted. This applies to all drives. Apply some grease to the Allen bolt and stud threads, and to the contact faces of the nuts and washers. Tighten the screws and nuts in diagonal sequence and evenly all around and with a torque of 38 Nm (28 lb.ft). Use tool 885008 and 885009