Section 06 DRIVE SYSTEM
Subsection 03 (DRIVEN PULLEY)
GENERAL
During assembly/installation, use the torque val-
ues and the service products as in the exploded
views.
Clean threads before applying a threadlocker. Re-
fer to SELF-LOCKING FASTENERS and LOCTITE
APPLICATION at the beginning of this manual for
complete procedure.
WARNING
Torque wrench tightening specifications
must strictly be adhered to.
Locking devices (e.g.: locking tabs, elastic
stop nuts, self-locking fasteners, cotter pins,
etc.) must be installed or replaced with new
ones where specified. If the efficiency of
a locking device is impaired, it must be re-
newed.
WARNING
Never start engine when the pulley guard is
removed.
WARNING
The driven pulley is a precisely balanced unit.
Never replace parts with used parts from an-
other driven pulley.
REMOVAL
Remove guard and drive belt from vehicle.
Remove driven pulley bolt no. 1 and shouldered
washer no. 2 then pull the driven pulley no. 3 from
the countershaft.
Note shouldered washer position for reinstalla-
tion. Take care not to lose spacer no. 4.
Countershaft
Should countershaft removal be required, refer to
CHAINCASE.
DISASSEMBLY
Use clutch spring compressor (P/N 529 035 524).
529 035 524
A30D0VA
TYPICAL
Remove half keys no. 5 and washer no. 6 to dis-
assemble the cam no. 7 and the 2 pulley halves.
WARNING
Driven pulley cam is spring loaded, use above
mentioned tool.
CLEANING
Large Bushing and Small Bushing
During break-in period (about 10 hours of use),
teflon from bushing no. 8 and no. 9 moves to cam
or shaft surface. A teflon over teflon running con-
dition occurs, leading to low friction. So it is nor-
mal to see gray teflon deposit on cam or shaft. Do
not remove that deposit, it is not dust.
When a dust deposit has to be removed from the
cam or the shaft, use dry cloth to avoid removing
transferred teflon.
Pulley Half Cleaning
Use pulley flange cleaner (P/N 413 711 809) to
clean pulley halves.
INSPECTION
Slider Shoe
Check cam slider shoes no. 10 for wear. Replace
when inside edge thickness of cam slider shoe
slope base is worn to 1 mm (.039 in) or less.
mmr2005-133 209
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