Intermediate Shaft Gear Replacement

[SCrescue]

Can anyone enlighten me on the best method of removing old gears and installing new gears onto the IS?

I've done several searches and haven't uncovered a recommended procedure.

Waynes "Rebuild" book mentions a procedure for reinstalling the drive gear onto the crank snout (heat it to 350? degrees in oil bath and then slide it on), but nothing for the IS gears.

Is it recommended or acceptable to use a universal gear puller to remove the old unit, or is there a special puller that must be used?

Can I simply press the new gears onto the shaft cold, or should the gears be heated first? If pressing them on, do I press them as far as they'll go until they hit the flange/boss, or is there a measurement involved?

Just thought I'd ask before I tackle it and mangle prefectly good parts due to ignorance.

Thx,

Mike

[cgarr]

They are a tight press fit, to remove them get a good puller that mates well with the back side of the gear, add pressure, a lot, then start to heat the gear and it will pop, then you can crank it off. To install I would freeze the shaft and heat the gear, lube and press it on.

[SCrescue]

Thanks Craig. Thought I'd post a follow-up with some additional comments in case anyone else could benefit down the road.

The sprockets are a VERY tight press fit. I initially tried using the Craftsman 8" 2 jaw puller pictured below. Per the advice posted, I applied substantial pressure with the puller and began to apply heat with a propane torch. Nothing. I applied increasingly more pressure and heat expecting to hear the pop. Nothing. I finally tightened the puller to the point that it started to get out of shape and decided to stop. Although only a 2 jaw puller, the 8" Craftsman is a substantial tool and I thought it would be enough for the job. It wasn't.

I then borrowed a buddy's monster Armstrong 3 jaw puller with cage (sorry, no picture, I'll try to take one next time I'm over his house)....what a horse....it was a bit unwieldy, but the sprockets put up zero resistance to the massive Armstrong puller without applying any heat. They simply broke loose as I began to apply moderate pressure. For anyone attempting this job, I highly recommend borrowing or renting the largest puller you can find, it makes all the difference. Also, I made sure to protect the fine tooth splined shaft on the small end with a plastic cap and used a 5/8 deep socket as an anvil for the puller to push against, and I used a very hefty metal spacer to protect the surface on the blunt end so as not to damage any surfaces.

Mike