Usage:
(1) Distance nut must be turned backwards and kept in place after installation of spring ... 1.5 mm (.06 in)
8Y2735 Spring:
Assembled length ... 367.5 mm (14.47 in)
Free length ... 482.6 mm (19.00 in)
Force of spring after installation ... 73 ± 6 kN (8.2 ± .7 ton)
Outside diameter ... 168.2 mm (6.62 in)
(3) Diameter of shaft (new) ... 50.47 ± 0.025 (1.987 ± .001 in)
(4) Remove plug and fill idler with SAE 30W oil.
(5) Clearance between shaft and bearing (new) ... .076 ± .076 mm (.003 ± .002 in)
(6) Torque for the bolts that hold idler shaft ... 70 ± 15 N·m (51 ± 11 lb ft)
Then hit lock pin in place with a hammer and tighten bolt to a torque of ... 70 ± 15 N·m (51 ± 11 lb ft)
(7) Clearance between frame and guide plate (each side) ... 1.5 mm (.06 in)
(8) Rubber torics and all surfaces contacting them must be clean and dry at assembly. Apply a thin film of oil to contacting surfaces of the metal seal rings just prior to assembly. Seal rings must be assembled square with the bore and the torics and must not be bulged or twisted. Put lubricant on all other seals at assembly.
D5C (9DL, 6ZL)
Fill idler with SAE 30W oil.
(1) Distance nut must be turned backwards and kept in place after installation of spring ... 1.5 mm (.06 in)
(2) 8Y6659 Spring:
Assembled length ... 404.6 ± 1.5 mm (15.93 ± .06 in)
Free length ... 530.0 mm (20.87 in)
Force of spring after installation ... 87 ± 7 kN (9.8 ± .8 ton)
Outside diameter ... 171.45 mm (6.750 in)
(3) Diameter of new shaft ... 53.924 ± 0.025 mm (2.1230 ± .0010 in)
(4) Clearance between new shaft and bushing ... 0.406 ± 0.055 mm (.0160 ± .0022 in)
(5) Torque for the bolts that hold idler shaft ... 70 ± 15 N·m (50 ± 11 lb ft)
Then hit lock pin in place with a hammer and tighten bolt to a torque of ... 70 ± 15 N·m (50 ± 11 lb ft)
(6) Clearance between frame and guide plate (each side) ... 1.5 mm (.06 in)
(7) Rubber torics and all surfaces contacting them must be clean and dry at assembly. Apply a thin film of oil to contacting surfaces of the metal seal rings just prior to assembly. Seal rings must be assembled square with the bore and the torics and must not be bulged or twisted. Put lubricant on all other seals at assembly.