0438046 JOHNSON GEARCASE, Complete

Start By:
Install the wheel chocks. Refer to Disassembly and Assembly, "Wheel Chock (Front and Rear) - Remove and Install".
Connect the frame lock link. Refer to Disassembly and Assembly, "Frame Lock Link - Separate and Connect".
Personal injury can result from hot oil or hot components.At operating temperature, oil is hot and under pressure. Hot oil can cause burns.Remove the fill cap only when the engine is stopped, and the fill cap is cool enough to touch with your bare hand.Do not allow hot oil or components to contact skin.
Note: Install caps and plugs on all openings in order to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal components.Note: For easier assembly, mark all hose assemblies, tube assemblies, wire harnesses and cables for identification purposes.
Illustration 1 g00597035
Remove bolt (1), the washer, and the clip that holds tube (2) to the engine.
Illustration 2 g00597039
Remove clamp (5) that holds breather assembly (4) to cover assembly (6). Repeat this procedure for the remaining clamp.
As a unit, remove breather assembly (4), tube (2), and hose tee (3) from cover assembly (6) .
Illustration 3 g00597040
Remove O-ring seals (7) from cover assembly (6). Repeat this procedure for the remaining O-ring seal.
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Remove clamp (9) that holds breather assembly (4) to hose tee (3). Remove breather assembly (4) from hose tee (3). Repeat this procedure for the remaining breather assembly (8) .
Remove clamp (10) that holds tube (2) to hose tee (3). Remove tube (2) from hose tee (3) .Installation Procedure
Note: Verify that all of the components of the breather are clean and free of foreign material prior to installation.Note: Check all of the O-ring seals and the components for wear or damage. Replace the components, if necessary. Lubricate the O-ring seals lightly with the lubricant that is being sealed.
Illustration 5 g00597042
Position tube (2) to hose tee (3), as shown. Tighten clamp (10) that holds tube (2) to hose tee (3) to a torque of 3 .5 N m (27 4 lb in).
Position breather assembly (4) to hose tee (3), as shown. Tighten clamp (9) that holds breather assembly (4) to hose tee (3) to torque of 3 .5 N m (26 4 lb in). Repeat this procedure for the remaining breather assembly (8) .
Illustration 6 g00597040
Install O-ring seal (7) to cover assembly (6). Repeat this procedure for the remaining cover assembly.
Illustration 7 g00597039
As a unit, position breather assemblies (4) and (8), hose tee (3), and tube (2), as shown. Tighten clamp (5) that holds breather assembly (4) to cover assembly (6) to a torque of 3 .5 N m (26 4 lb in). Repeat this procedure for the remaining clamp.
Illustration 8 g00597035
Install bolt (1), the washer, and the clip that holds tube (2) to the engine.End By:
Separate the frame lock link. Refer to Disassembly and Assembly, "Frame Lock Link - Separate and Connect".
Remove the wheel chocks. Refer to Disassembly and Assembly, "Wheel Chock (Front and Rear) - Remove and Install".