Re: Driveshaft Pinion Nut removal help
It's not too difficult if you know the trick. And the procedure is in the manual that you should buy if you intend to continue to work on the engine.
The nut is a 3/4 right hand thread. However, it is torqued onto the shaft at 85 foot pounds so it is tight. You must use a 3/4 six point socket and a 1/2 inch breaker bar. Wedge a block of hard wood behind the socket and breaker bar to keep it from slipping off the nut. Pad the breaker bar handle well where it contacts the aluminum case. There is a special tool to adapt to the splines at the top of the shaft but I have found that if you are careful and pad them well, a Vise Grips will work. Clamp them firmly onto the splines and whack them with a rubber mallet. If you have an old crankshaft lying around, use it instead and you will definitely not mess the splines. After you remove the nut, hold the shaft vertical and whack the case with a rubber mallet to pop off the pinion--it will not just fall off.
Factory recommends a new pinion nut torqued to 85 ft. lbs. but I have not had problems re-using the old one.
Now, you say the clutch is slipping. The dog clutch can not slip--it can disengage and re engage with a bang.
If this is your problem, the dogs on the clutch and gears are worn and rounded. They CAN be re-ground square with a dremel and a carbide bit or better yet a stone. Drill press is a little more accurate.
Since the forward dogs get 90% of the wear, sometimes if the forward gear is not worn too badly, you can just reverse the clutch and presto-zingo--- you are on your way for a couple of seasons more. And this is without removing the pinion and forward gear.
If you do elect to remove the pinion, be certain to retain all the shims from the top bearing--they locate the pinion in relation to the other two gears. Lose one and your gears will self-destruct in short order.
When you do re-attach the pinion, be certain to torque the nut to 85 ft lbs. This is important because aside from having the nut tight enough to not work loose, it ALSO locates the pinion gear on the taper and in relation to the other two gears.
