Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | 1P-0520 | Driver Gp | 1 |
B | 138-7575 | Link Bracket | 4 |
C | 138-7573 | Link Bracket | 2 |
D | 1H-3107 | Bearing Puller | 1 |
1H-3108 | Push-Puller Leg | 2 | |
1H-3110 | Bearing Puller | 1 | |
5F-7366 | Screw | 1 | |
5F-7351 | Nut | 1 | |
5F-7353 | Washer | 1 | |
6V-3160 | Double Acting Cylinder | 1 | |
4C-4865 | Manual Hydraulic Pump | 1 | |
E | 5F-7353 | Washer | 1 |
6V-3160 | Double Acting Cylinder | 1 | |
4C-4865 | Hand Hydraulic Pump | 1 | |
1P-1839 | Bearing Puller Adapter | 1 | |
8S-6587 | Adapter | 1 | |
9S-5559 | Stud | 1 | |
1M-6756 | Sleeve Assembly | 1 | |
9H-3992 | Head | 1 | |
1P-9543 | Nut | 1 | |
F | 8B-7554 | Bearing Cup Puller | 1 |
8B-7548 | Bearing Puller | 1 | |
8H-0684 | Ratchet Wrench | 1 | |
G | 8B-7548 | Bearing Puller | 1 |
8B-7551 | Bearing Puller | 1 | |
9S-9154 | Step Plate | 1 | |
8H-0684 | Ratchet Wrench | 1 | |
H | 8B-7554 | Bearing Cup Puller | 1 |
8B-7548 | Push-Puller Tool Gp | 1 | |
8B-7549 | Puller Leg | 2 | |
8H-0684 | Ratchet Wrench | 1 | |
J | 8B-7548 | Push-Puller Tool Gp | 1 |
8B-7551 | Bearing Puller | 1 | |
5P-4170 | Step Plate | 1 | |
8H-0684 | Ratchet Wrench | 1 |
Start By:
- Separate the output transfer gears from the transmission. Refer to Disassembly and Assembly, "Transmission from Output Transfer Gears - Separate".
Note: Cleanliness is an important factor. Before you begin the disassembly procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism. Precision components can be damaged by contaminants or by dirt. Perform disassembly procedures on a clean work surface. Keep components covered and protected at all times.
NOTICE |
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Failure to properly assemble parts or failure to follow established procedures can lead to damage of the parts and assembly. To avoid damage to parts, always identify and mark the parts so that they can be installed in the same location. Ensure that gear surfaces align. Never force parts during assembly. |
- Remove bolt (1) and retainer (2) from yoke (3).
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Illustration 2 g01094116 - Remove O-ring seal (4) and yoke (3).
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Illustration 3 g01094117 - Remove eight bolts (5) from bearing cage (6).
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Illustration 4 g01094118 - Use two bolts (5) as forcing screws in order to separate bearing cage (6) from transfer gear case (7).
- Remove bearing cage (6) from transfer gear case (7).
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Illustration 5 g01094119 - Remove lip seal (8) from bearing cage (6).
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Illustration 6 g01094120 - Use Tooling (A) in order to remove bearing cup (9) (not shown) from bearing cage (6).
- Remove O-ring seal (10) from bearing cage (6).
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Illustration 7 g01094121 - Install Tooling (B) to transfer case. Attach suitable lifting chains and a hoist to Tooling (B).
- Turn transfer gear case (7). The weight of transfer gear case (7) is approximately
520 kg (1150 lb) .Show/hide tableIllustration 8 g01094123 - Remove bolt (11) and retainer (12) from yoke (13).
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Illustration 9 g01094125 - Remove O-ring seal (14) and yoke (13).
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Illustration 10 g01094126 Note: The bolts are different lengths. Identify the bolts for installation purposes.
- Remove 11 bolts (15) from bearing cage (16).
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Illustration 11 g01094128 - Use two 3/8 inch bolts as forcing screws in order to separate bearing cage (16) from transfer gear case (7).
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Illustration 12 g01094131 - Install Tooling (C) to bearing cage (16). Attach a suitable hoist and lifting chains to Tooling (C). The weight of bearing cage (16) is approximately
95 kg (210 lb) . - Remove bearing cage (16) from transfer gear case (7).
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Illustration 13 g01094132 - Remove O-ring seal (17) from bearing cage (16).
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Illustration 14 g01094133 - Use Tooling (D) in order to remove shaft (18) from bearing cage (16).
- Remove the spacer and gear (19) from shaft (18).
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Illustration 15 g01094134 - Remove lip seal (20) from the bearing cage.
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Illustration 16 g01094135 Show/hide tableIllustration 17 g01094136 - Turn bearing cage (16).
- Remove six bolts (21) and retainer (22) from bearing cage (16).
- Use Tooling (E) in order to remove two bearing cones (23) and one bearing cup from the bearing cage.
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Illustration 18 g01094137 - Use Tooling (F) in order to remove the other bearing cup from bearing cage (16).
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Illustration 19 g01094138 - Use Tooling (G) in order to remove bearing (24) from shaft (18).
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Illustration 20 g01061245 - Remove nine bolts (25) and cover (26) from gear case cover (27).
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Illustration 21 g01094139 - Remove O-ring seal (28) from cover (26).
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Illustration 22 g01061246 - Remove eight bolts (29) from bearing cage (30).
- Use two bolts (29) as forcing screws in order to separate bearing cage (30) from gear case cover (27).
- Remove bearing cage (30) and shim pack (31) (not shown) from gear case cover (27).
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Illustration 23 g01094140 - Use Tooling (H) in order to remove bearing cup (32) from bearing cage (30).
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Illustration 24 g01094141 - Remove four nuts (33) from cover (34).
- Remove cover (34) from bearing cage (35).
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Illustration 25 g01094142 - Remove O-ring seal (36) from bearing cage (35).
- Remove seven bolts (37) from bearing cage (35).
- Use two bolts (37) as forcing bolts in order to separate bearing cage (35) from the gear case cover.
- Remove bearing cage (35) and shim pack (38) (not shown) from the gear case cover.
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Illustration 26 g01094143 - Remove O-ring seal (39) from bearing cage (35).
- Use Tooling (H) in order to remove bearing cup (40) from bearing cage (35).
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Illustration 27 g01061247 - Remove two bolts (41) and drain assembly (42) from transfer gear case (7).
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Illustration 28 g01061248 - Remove eight bolts (43) from gear case cover (27).
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Illustration 29 g01061694 - Install tooling (C) to gear case cover (27).
- Attach suitable lifting chains and a hoist to Tooling (C). The weight of gear case cover (27) is approximately
45 kg (100 lb) . - Remove gear case cover (27) from transfer gear case (7).
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Illustration 30 g01061251 - Remove speed sensors (44) and (45) from transfer gear case (7).
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Illustration 31 g01061253 - Attach a suitable lifting sling and a hoist to gear (46). The weight of gear (46) is approximately
39 kg (86 lb) . - Remove gear (46) from the transfer gear case.
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Illustration 32 g01061254 - Use Tooling (J) in order to remove two bearing cones (47) from gear (46).
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Illustration 33 g01061255 - Attach a suitable lifting sling and a hoist to gear (48). The weight of gear (48) is approximately
29 kg (64 lb) . - Remove gear (48) from the transfer gear case.
- Use Tooling (F) (not shown) in order to remove the two bearing cups (49) and (50) from the transfer gear case.
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Illustration 34 g01061256 - Remove two bearing cones (51) from gear (48).
Illustration 1 | g01094114 |