0435476 JOHNSON GEARCASE., Complete

1. Remove two bolts (2), and pull housing (1) from the end of the tube to remove it from the engine. 2. Remove the bolts to remove cover (3) and the screen from housing (1). 3. Remove bolts (6) to remove clips (7) and brackets (5) from tube (4).4. Pull tube (4) from the scavenge pump, and remove tube (4) from the engine. Remove the O-ring seals from the tube. 5. Remove two bolts (8) and remove elbow (9) from the oil scavenge pump.6. Remove four bolts (11), and use two men to remove oil scavenge pump (10) from the engine. The weight of the pump is 32 kg (71 lb). The following steps are for installation of the oil scavenge pump.7. Use two persons to put oil scavenge pump (10) in position, and install the bolts to hold the pump to the engine block.8. Install the O-ring seals on both ends of tube (4), and put clean engine oil on the seals. Put tube (4) in position in the scavenge pump.9. Put clips (7) and brackets (5) in position on tube (4). Install bolts (6) to hold clips (7), brackets (5) and tube (4) in position on the engine block.10. Clean and inspect the screen and make a replacement if necessary. Put the screen and cover (3) in position on housing (1). Install the bolts to hold these in position.11. Put housing (1) in position on the end of tube (4), and install the bolts to hold the housing in position.End By:a. install oil panDisassemble & Assemble Oil Scavenge Pump
Start By:a. remove oil scavenge pump On later models, gear (2) is mounted directly to the shaft and there is no flange. Use tooling (B) to remove the gear in the same manner the flange is removed in Step 3.1. Loosen bolt (1). Do not remove the bolt at this time. 2. Remove bolts (3) to remove gear (2) from the flange. 3. Use tooling (A) to loosen the flange from the drive shaft. Remove tooling (A), the bolt, washer and flange from the drive shaft. 4. Put alignment marks on the pump body and cover (5) for correct assembly. Remove bolts (4) to remove cover (5) from the pump body. 5. If necessary, remove dowels (6) and bearings (7) from cover (5). 6. Remove drive shaft assembly (8) and idler shaft assembly (9) from the pump body. 7. If necessary, remove bearings (10) from the pump body. The following steps are for the assembly of the oil scavenge pump. Put clean engine oil on the shaft assemblies and bearings when the pump is assembled. 8. Use tool group (B) to install bearings (10) until they are 1.5 0.5 mm (.06 .02 in) below the bottom of the gear bores in the pump body. Make sure the joints in the bearings are in the position shown.9. Check the inside diameter of bearings (10) after they are installed. The inside diameter must be 31.837 0.070 mm (1.2534 .0028 in).10. If necessary, make a replacement of the gears on shaft assemblies (8) and (9). Heat the gears to a maximum temperature of 316° C (600° F), and install the gears on the shaft assemblies. The face of the gear on drive shaft assembly (8) must be 60.00 0.25 mm (2.362 .010 in) from the threaded end of the shaft. The ends of idler shaft assembly (9) must be 34.0 0.5 mm (1.34 .02 in) from the gear faces.11. Install idler shaft assembly (9) and drive shaft assembly (8) in the pump body. 12. Use tool group (B) to install bearings (7) in cover (5). Install bearings (7) with the joints in the position shown. Make sure the bearings are 1.5 0.5 mm (.06 .02 in) below the surface of cover (5).13. Check the inside diameter of bearings (7) after they are installed. The inside diameter must be 31.837 0.070 mm (1.2534 .0028 in).14. Install dowels (6) in cover (5) until they are 6.4 0.5 mm (.25 .02 in) above the surface of cover (5) as shown.15. Put cover (5) in position, and install the bolts to hold it to the pump body.16. Put the flange in position on the drive shaft assembly.17. Install the washer and bolt (1).18. Put gear (2) in position on the flange so the chamfer for the gear bore is next to the flange. Install bolts (3) that hold the gear to the flange.19. Seat gear (2) by hitting the gear with a soft-faced hammer and tighten bolts (3) again, as necessary.End By:a. install oil scavenge pump