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301 viewsTaken apart with the rear case fully removed.
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300 viewsCloser-up. Exploded view. Notice pin is short...it came to us broken.
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305 viewsLeft to right: Rear of gear box with rearward ring, laying on table is planetary ring, behind that is the forward ring, and behind that is a thin plastic washer.
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306 viewsInside of forward gear and planetary gear mating teeth.
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305 viewsInside of rearward gear and planetary gear mating teeth.
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298 viewsRearward gear with original grease. The "B" means back lift box.
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311 viewsThe pin is missing. Looks melted...??? Without this pin set in the case halves the planetary ring rotates and doesn't allow the forward gear to rotate properly.
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307 viewsAll the bearings are roller bearings and they are held in with the grease. When cleaning the grease and wiping the bearings they will most likely fall out so work over a soft, plush towel to keep them from bouncing away. Pack the bearings and cage surfaces with fresh grease and slip any fallen bearings back in. You should see no gaps between the bearings. Pack more grease in when they're all in and roll them around with your finger to spread the fresh grease around. It will hold them in there.
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307 viewsI ground the planetary pin level and then drilled a 3/16" hole in it to a half-inch depth. I got a piece of 3/16" rod from the local hardware store, beveled the edge, then pushed it into the hole.
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310 viewsThe new pin in the hole, ready for welding.
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302 viewsPin welded in and ground. The gears are plastic and so after each weld you need to dip the pin into water to cool it down otherwise the plastic holding the pin will melt...as I found out. But the plastic didn't melt too badly and the original pin is still secure.
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304 viewsPlanetary gear in position and pin marked where it needs to be cut.
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308 viewsRepaired pin cut, ground further, and beveled. Fits in the hole nicely! Remember, the planetary ring will move side-to-side so make sure the pin isn't butted against the end of the hole. Allow for the movement.
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308 viewsBearing grease (red) applied on the planetary teeth for mating to the rearward gear. I followed the instructions for the "new" teeth so I hope this is okay for the "old" teeth. I think it should be.
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307 viewsSame thing for forward gear.
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318 viewsIndexes all lined up. Ready for the case halves to be mated now.
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318 viewsThe repaired pin in place. Thin plastic washer goes between the gear (front and rear gears) and the case.
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Reference: Rear gear box, rear side.315 viewsRear side of rear gear box. Steel roll pin is 3/16" diameter by 1-1/2" long. This is where the crank handle connects. The zinc washer is 2" diameter with a 3/4" hole and is a tad thicker than the original one (I couldn't find a thin one). The grommet between the washer and case is 1-5/8" outside diameter (OD) and 1/4" thick so it's just slightly thinner than the original one.
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Reference: Rear gear box, front side.311 viewsFront side of rear gear box. Steel roll pin is 3/16" x 1-1/4". This is where the drive shaft fits.
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318 viewsPermatex 2A gasket silicone is what I smeared on the mating surfaces of the case half instead of using a gasket.
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