6B-40 - LOWER UNIT 90-824052R3 JUNE 2002
5. Position lubrication sleeve (if equipped) in drive-
shaft bore.
a
c
b
51870
a - Lubrication Sleeve
b - Tab (MUST align with slot)
c - Slot
6. Sport Master only: Do not install lower bearing
cup shims or cup at this time. Lower cup and
shims coud interfer in achieving an accurate
pinion height.
7. Position pinion gear in gear housing below drive-
shaft bore with teeth of pinion gear meshed with
teeth of reverse gear.
8. Insert driveshaft into driveshaft bore while
holding pinion gear. Rotate driveshaft to align
and engage driveshaft splines with pinion gear
splines. Continue to insert driveshaft into gear
housing until driveshaft tapered bearing is
against bearing race.
9. Place a small amount of Loctite 271 onto threads
of pinion gear nut and install flat washer and nut
on driveshaft with flat side of nut away from pinion
gear. Hand tighten pinion nut.
10. Place shim(s) (retained from disassembly) into
gear housing. If shim(s) were lost or are not
reusable (damaged), start with approximately
0.010″ (0.254mm).
11. Install bearing race and bearing retainer.
d
b
a
c
51880
e
a - Shim(s)
b - Bearing Race
c - Bearing Retainer (Word “OFF” must be visible);
Torque to 100 lb. ft. (135.5 N·m)
d - Bearing Retainer Tool (91-43506)
e - Sport Master Gear Case Upper Bearing Shim Location
12. Use a socket and flex handle to hold pinion nut
(pad area where flex handle will contact gear
housing while torquing nut).
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