Usage:
start by:
a) remove clutch hubs
1. Turn the transmission housing as shown.
2. Remove bolts (1) that hold rear cover to the housing.
3. Install two 7/16"-14 NC forged eyebolts and tooling (A) to the rear cover. Fasten a hoist to the eyebolts and the tooling.
| NOTICE |
|---|
The pinion gear assemblies can fall against the housing and cause damage to the bearings. |
4. Remove main drive gear and output shaft assembly (2) slowly to prevent damage to the pinion gear assemblies. Weight is 565 lb. (254 kg). Remove tooling (A) and the two eyebolts.
5. Remove pinion gear assemblies (3).
6. Remove two bearing cones (4) from the pinion gear with tooling (B) and a press.
7. Do Step 7 for the other pinion gear assembly.
8. Remove output shaft bearing cup (5) and two pinion bearing cups (6) from the housing, if necessary.
9. Fasten tooling (A) and a hoist to main drive gear and output shaft assembly and rear cover (2). Lift the assembly as shown.
10. Remove O-ring seals (7) and (8) from the rear cover.
Install Main Drive Gear And Output Shaft
1. Check all parts for damage. If damaged, use new parts for replacement.
2. Make sure all parts are clean and free of dirt and foreign material.
3. Fasten tooling (A) and a hoist to main drive gear and output shaft assembly and rear cover (1). Lift the assembly as shown. Weight is 565 lb. (254 kg).
4. Install O-ring seals (2) and (3).
5. Install the two pinion bearing races with tooling (B) in the housing if removed.
NOTE: The output shaft bearing cup can be installed with acceptable tooling.
6. Lower the temperature of the output shaft bearing cup (4) and install in the housing, if removed.
7. Heat two bearing cones (5) to a maximum temperature of 275°F (135°C).
8. Put bearing cones (5) in position on the pinion gear.
| NOTICE |
|---|
When bearing cones (5) get cool, use a force of 16,000 to 20,000 lb. (71 200 to 89 000 N) to push the cones against the shoulders on the pinion gear. |
9. Do Steps 7 and 8 for the other pinion gear.
10. Put pinion gear assemblies (6) in position in the housing.
NOTE: Put 7M7260 Liquid Gasket Material on the contact surfaces between the rear cover and the housing.
11. Install two 7/16"-14 NC forged eyebolts (7) and tooling (A) to main drive gear and output shaft assembly (8). Fasten a hoist to the eyebolts and the tooling.
| NOTICE |
|---|
Make an alignment of pinion gears and main drive gear. |
12. Lower the assembly slowly into the housing. Make sure pinion gears are in alignment. Install the bolts that hold the rear cover in position.
end by:
a) install clutch hubs
Disassemble Main Drive Gear And Output Shaft
start by:
a) remove main drive gear and output shaft
1. Remove bolts (1) and retainer (2).
2. Install tooling (A). Remove bearing cone (4) and main drive gear (3). Weight of gear is 260 lb. (117 kg).
3. Remove key (5).
4. Turn the rear cover and the output shaft as shown and put in position on wood blocks. Weight is 305 lb. (137.3 kg).
5. Remove bolts (6).
6. Install two 7/16"-14 NC x 4 in. forcing screws (7). Loosen the output shaft assembly from the rear cover.
7. Fasten tooling (B) and a hoist to output shaft assembly (8). Remove the output shaft assembly. Weight is 140 lb. (63 kg).
8. Remove the output shaft bearing race and the two pinion bearing races from the rear cover, if necessary.
9. Remove bearing cone (9) from the output shaft with tooling (C). Remove the O-ring seal (not shown) from the cover.
9. Remove cover (11) from output shaft (10).
10. Remove seals (12) from the cover, if necessary.
Assemble Main Drive Gear And Output Shaft
1. Check all parts for damage. If damaged, use new parts for replacement.
2. Make sure all parts are clean and free of dirt and foreign material.
3. Install the inner seal with tooling (A) in cover (1). The lip of the inner lip type seal must be toward the transmission housing.
4. Turn tooling (A) as shown and install the outer seal in cover (1). The lip of the outer lip type seal must be away from the transmission housing.
5. Install the output shaft bearing cup and the two pinion bearing cups in the rear cover with acceptable tooling or lower the temperature of the races, if removed.
| NOTICE |
|---|
The temperature of the output shaft, the output shaft bearing cones and the main drive gear are changed to assemble the parts. Assembly of the parts must be done rapidly before the temperature of the parts become normal again. |
6. Lower the temperature of the output shaft to a maximum of -10°F (-23°C).
7. Heat the two output shaft bearing cones to a maximum temperature of 275°F (135°C).
8. Heat the main drive gear to a maximum temperature of 350°F (176.5°C).
NOTE: Put lubricant to be sealed on the lip of the lip type seals.
9. Put cover (3) on output shaft (2). Install O-ring seal (not shown) in the cover.
10. Install rear cover (4) over the output shaft. Use two persons. Weight is 165 lb. (74 kg).
11. Install bearing cone (5) and key (6) on the output shaft.
NOTE: Use three 1"-8 NC forged eyebolts, washers, nuts and a hoist to install the main drive gear. Weight is 260 lb. (117 kg). Make an alignment of the key and the key groove (slot) in the main drive gear.
12. Install main drive gear (7) on the output shaft.
13. Install bearing cone (9). Put retainer (8) in position.
14. Install three bolts (10) that hold the retainer in position. Tighten the bolts to a torque of 150 ± 20 lb.ft. (205 ± 25 N·m).
15. Install the six bolts that hold the cover to the rear cover.
end by:
a) install main drive gear and output shaft