Usage:
Remove Transfer Gears
START BY:
a. remove transmission and transfer gears
1. Remove yoke (1).
2. Remove the bolts that hold electronic speed sensor (3), and remove the sensor.
3. Remove cover (4), the O-ring seal and the magnetic screen from the transfer gear case.
4. Remove manifold assembly (2) from the transmission and transfer gears.
5. Remove electronic speed sensor shaft (6) from the transmission and transfer gears.
6. Fasten a hoist to the transfer gears as shown, and remove bolts (5).
7. Install two 1/2"-13 NC forcing screws (8) in the transfer gear case. Tighten the forcing screws evenly, and remove transfer gears (7) from the transmission. The weight of the transfer gears is 163 kg (360 lb.).
8. Remove the O-ring seals from the transmission.
Install Transfer Gears
1. Put O-ring seals (2), (3) and (4) in position on the transmission.
2. Put transfer gears (1) in position on the dowels in the rear of the transmission, and install the bolts.
3. Install electronic speed sensor shaft (5) in the transmission and transfer gears.
4. Make sure the O-ring seals are in place in manifold assembly (7), and install the manifold assembly on the transmission and transfer gears.
5. Put the magnetic screen in position in the transfer gear case. Put the O-ring seal in position in cover (9), and install the cover.
6. Put electronic speed sensor (8) in position on the shaft and transfer gear case, and install the bolts.
7. Put clean SAE 30W oil on the lip seal for the yoke, and install yoke (6).
END BY:
a. install transmission and transfer gears
Disassemble Transfer Gears
START BY:
a. remove transfer gears
1. Remove snap ring (2) with tool (A). Remove spacer (1) from shaft (3).
2. Remove shaft (3) from the transfer gears.
3. If necessary, remove bearing (4) from shaft (3).
4. Remove the bolts that hold cage (7) to transfer gear case (5). Install two 3/8"-16 NC forcing screws (6) in the cage. Tighten the forcing screws evenly, and remove the cage and the shims from the transfer gear case.
5. Remove bearing cup (8) from cage (7).
6. Remove gear (9) from the transfer gear case.
7. If necessary, remove two bearing cones (10) from gear (9).
8. If bearing cup (11) is damaged, remove the bearing cup from the transfer gear case.
9. Remove the bolts that hold cage (12) to transfer gear case (5). Install two 3/8"-16 NC forcing screws (6) in the cage. Tighten the forcing screws evenly, and remove the cage and shims from the transfer gear case.
10. Remove O-ring seal (15) and lip-type seal (14) from cage (12).
11. If necessary, remove bearing cup (13) from cage (12).
12. Remove gear (16) from transfer gear case (5).
13. If necessary, remove two bearing cones (17) from the gear.
14. Remove bolt (19), and remove tube assembly (18) from the transfer gear case.
15. If necessary, remove bearing cup (20) from the transfer gear case.
Assemble Transfer Gears
1. Clean and inspect all parts. Replace all parts that are worn or damaged.
2. If bearing cup (4) was removed from the transfer gear case, lower the temperature of the bearing cup, and install it in transfer gear case (1).
3. Install tube (2) and clip (3) in the transfer gear case. Install the bolt that holds clip (3) to the case, and bend the end of the clip over the side of the bolt.
4. If bearings (5) were removed from the gear, heat the bearings to a temperature of 135°C (275°F), and install the bearings on gear (6).
5. Put gear (6) in position in transfer gear case (1).
6. If bearing cup (7) was removed from the cage, lower the temperature of the bearing cup, and install it in cage (9).
7. Put 7M7260 Liquid Gasket Material in the seal base of cage (9), and let the liquid gasket material dry. Install lip-type seal (8) in cage (9) with this lip toward the inside as shown. Put clean SAE 30W oil on the lip of the seal.
8. Put O-ring seal (10) in position in the groove in cage (9). Put clean SAE 30W oil on the O-ring seal.
9. Install the original shims and cage (9) on the transfer gear case. Use tooling (B) to measure the end play of gear (6). Subtract or add shims between the cage and the transfer gear case to get an end play measurement of 0.15 ± 0.05 mm (.006 ± .002 in.).
10. If bearing cup (11) was removed from the transfer gear case, lower the temperature of the bearing cup, and install it in the transfer gear case.
11. If bearings (12) were removed from the gear (13), heat the bearings to a temperature of 135°C (275°F), and install them on gear (13).
12. Put gear (13) in position in the transfer gear case.
13. If bearing cup (15) was removed from the cage, lower the temperature of the bearing, and install it in cage (14).
14. Install the original shims and cage (14) on transfer gear case (1). Use tool (B) to measure the end play of gear (13). Add or subtract shims between cage (14) and transfer gear case (1) to get an end play measurement of 0.15 ± 0.05 mm (.006 ± .002 in.).
15. Install bearing (17) in shaft (16) with tool (C). Install the bearing 6.0 ± 0.5 m (.236 ± .002 in.) below the end of the shaft.
16. Check the diameter of the bearing. The diameter of the bearing must be 12.774 ± 0.034 mm (.503 ± .001 in.) after installation.
17. Put shaft (16) in position in gear (13).
18. Put spacer (18) in position on shaft (16), and install snap ring (19) on the shaft with tool (D).
END BY:
a. install transfer gears