IDLER & BEARING AS 6Y1189 - Caterpillar

After repairs are made to a transmission, inspect the forks and gears for correct alignment. On a correctly assembled transmission, gears (R) and (S), on the upper shaft must be free to slide .10 to .51 mm (.004 to .020") on the splines between ring (X) and spacer (Y). See Illustration 1. If the gears are not free to slide as specified, grind the small end of one of the gears to get the correct clearance.
Illustration 1. Location of components on upper shaft.Install the interlock mechanism but do not install the upper part of the gear shift control to the top of the transmission. Make a shift of the transmission through all speed ranges including neutral. After each shift, make a rotation of the interlock lever. It must turn freely. Any resistance to rotation is an indication that a plunger does not have a good seat in the fork detent or that a fork is either bent or not made correctly. Make a replacement of a fork, if necessary. After each shift is made, check each gear for correct alignment. When two gears with different widths are engaged, the narrower gear must be in the center of the wider gear. Gears that are not engaged, but are in a location between two gears, must be centered (same distance from each gear) so that no gear end contact will be heard during rotation.
If a gear is not in correct alignment with a gear it runs against because of worn or bent forks, it is our recommendation to make a replacement of the fork with a new one.
After installation of the transmission, make the adjustments and checks that follow: 1. Adjust the linkage to the flywheel clutch lever to get the 175 mm (6.9") reference dimension, as shown in Illustration 2.2. Adjust the flywheel clutch control linkage shown in Illustration 2. With clutch lever (B) in the engaged position, adjust linkage (C) until dimension (A) is correct.3. Adjust the flywheel clutch interlock linkage. See Illustration 3.
Illustration 2. Flywheel clutch control linkage.
Illustration 3. View AA from Illustration 2. Flywheel clutch interlock linkage.a. Loosen the locknut on rod assembly (F).b. With flywheel clutch lever (B) not engaged, turn rod end (G) to decrease dimension (E) until movement of rod assembly (F) is felt while a shift of the transmission is made.c. When movement is felt, turn rod end (G) two full turns to increase dimension (E). This will give the correct alignment of the plungers and lockout shaft. Tighten the locknut to 12 4 N m (105 35 lb in).4. Look at the interlock spring (K) while a shift of the transmission is made through all speed ranges. Use the flywheel clutch each time. The length of the spring must not change because of any compression force against it. If the spring length changes, it is an indication that the linkage does not move freely or that the interlock does not have correct contact with a plunger.On D5B LGP Tractors,