129
ii. Remove drain plug(s).
c) Inspect magnetic drain plug for metal fragments or other abnormalities that may
provide clues as to condition of internal gearbox components. (See Section 5.1,
Troubleshooting.)
d) Install magnetic (and/or adjacent) drain plug(s).
i. Hand start drain plug.
ii. Using 9/16-in wrench (or 8 pt. socket and ratchet – set for CW), tighten mag-
netic drain plug. NOTE: If required using 10 mm hex socket and ratchet – set
for CW, tighten adjacent drain plug.
Using seal removal tool, remove input shaft endcap (located on pump 2.
side of gearbox).
a) Drive removal tool into input shaft endcap.
b) Pry input shaft endcap out of gearbox.
NOTES
The endcap is NOT serviceable after removal.
If a heavy enough tool is NOT available, using a hammer drive a long thin chisel into
the endcap, then use a short length of steel rod as a fulcrum and pry (the hammer
may again be used) the endcap out of the gearbox.
B. Discard endcap.
Input Shaft Endcap Installation
A. Install new input shaft endcap.
Apply Loctite 680 (or equivalent) to mating surface of new endcap. 1.
Place endcap over gearbox opening with smooth part of cap facing out-2.
ward.
Using seal driver, drive endcap into gearbox until flush. 3.
B. Perform Gearbox Oil Level Check. (Refer to paragraph 4.3.2.)
This procedure may require gearbox installation after performance. If so, use paragraph 5.9.1
(on page 118) for instructions to reassemble the gearbox and pump assemblies (unit) and para-
graph 5.8.8 (on page 117) to install the unit on the apparatus after this bench procedure is
completed.
5.9.2.1.4 Drive Gear (Input Shaft)
The input shaft turns the drive gear, which mates with and drives the pump gear, which turns the
pump shaft. The pump shaft turns faster than the input shaft, how much faster depends on the
GR selected. The Flex series gearbox design requires gearbox cover removal for gear set access
and pump gear removal for dive gear removal. If the drive gear requires R&R the pump gear re-
quires close inspection to check for possible damage requiring pump gear R&R. Inspect for dam-
aged and/or worn teeth, indications of overheating, stress cracking, etc.
This procedure requires unit removal from the apparatus followed by pump removal from the
gearbox prior to performance to provide input shaft access. See paragraph 5.9.2 (on page 120)
for reference to the required Removal From The Apparatus and Gearbox R&R procedures.
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