np205 Rebuild Question....Idle Shaft

[kilomanjaro]

I just installed the idle shaft and gear in the np205 I am rebuilding. I know you are supposed to install the shims and spacer between the bearings and check the end play. I thought I was good with zero end play, but then I installed the idle gear/shaft into the case and torqued the shaft nut to 135 lb.ft (also read it is supposed to be 200) I installed the same 3 shims that came out of the assembly. I had new races put into the idler gear. When I tried to torque down the nut it just froze the gear assembly. I backed off the nut and reset to about 75lb.ft. It spun freely without any binding and there was zero end play in the gearset. Do I need to pull it out and add a shim so I can torque to 135 (or 200) lb.ft? Advice from anyone with some experience here would be much appreciated. Thanks
John

[jbclassix]

.001-.002 end play. 135lbft.

There is a spacer sleeve that goes between the shims and one of the bearings. Do you have that installed?

[kilomanjaro]

Yes I put the shims in, I ordered some more shims last night from some website....quad 4x4 I think.....$35!!!...I need to add some to get the space between the bearings set right. I'm not sure why I need so much more shim after putting new races/bearings in.
Thanks
John
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[jbclassix]

I was referring to the sleeve that is pictured between the shims and the bearing. without it the bearings will just LOCK when the nut is torqued. Hope that helps.

[kilomanjaro]

Yes I put the sleeve in too....the bearing races must be a little different somehow. thanks
John
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[jbclassix]

You may laugh at this picture, but this is how I pre-loaded my bearings to set my shim pack before installing it. I am almost done rebuilding my 205. I photo documented the whole thing. I will post them up once it is all back together.