Usage:
NOTE: This transfer gear box is used on the following model and serial numbers: 428B, 7EJ1-UP.
1. Drain the oil from the transfer gear box.
2. Put a floor jack underneath the transfer gear box.
3. Disconnect electrical wiring (1).
4. Remove bolts (2) to remove transfer gear box (3). The weight of the transfer gear box is 34 kg (75 lb).
NOTE: The following steps are for the installation of the front drive transfer gear box.
5. Put transfer gear box (3) in position with the floor jack and install bolts (2). Tighten the bolts to a torque of 45 to 64 N·m (33 to 47 lb ft).
6. Connect electrical wiring (1).
7. Fill the transfer gear box with oil to the correct level. See the Operation And Maintenance Manual.
Disassemble Front Drive Transfer Gear Box (428B)
Start By:
a. remove front drive transfer gear box.
1. Remove bolts (2), cover (1) and the gasket.
2. Remove spacer (6) and shims (5). Bend back the tab on lockwasher (3). Remove nut (4) and lockwasher (3).
3. Remove spacer (7) from the shaft.
4. Bend back the tab on lock (9). Remove bolt (8), lock (9) and washer (10).
5. Remove O-ring seal (11) and yoke (12). Remove bolts (14) and adapter assembly (13).
6. Remove O-ring seal (16) from the transfer gear case. Remove seal rings (15) from the shaft.
7. Remove O-ring seals (17) from the adapter.
8. Remove bolt (18) and remove a spring and spool from the solenoid cavity. Remove the lip-type seal from the other side of the adapter.
9. Put the transfer gear box in position in a press and push the shaft and bearing assembly from the clutch and gear assembly.
10. Remove clutch and gear assembly (19) from the transfer gear case.
11. Check the condition of bearing race (20) and remove it if necessary.
12. Disassemble the clutch and gear assembly as follows:
a. Remove cylinder (21) and piston assembly (22).
b. Remove spring assembly (24) from the piston assembly. Check seals (23) and (27), and remove them if necessary.
c. Remove hub gear (28), thrust washer (25) and clutch assembly (29) from gear assembly (26).
d. Remove bearing and sleeve assembly (30). Remove washer (31). Remove the bearings from the sleeve.
Assemble Front Drive Transfer Gear Box (428B)
NOTE: This transfer gear box is used on the following model and serial numbers: 428B 7EJ1-UP.
1. Assemble clutch and gear assembly (3) by reversing the procedures shown in steps 12a - 12d. Do not assemble bearing and sleeve assembly (30) at this time.
2. Put clutch and gear assembly (3) in position in the transfer gear case. Install seals (1) on the shaft and bearing assembly.
3. Put shaft and bearing assembly (2) in the clutch and gear assembly.
4. Press the shaft into the clutch and bearing assembly as shown.
5. Turn the transfer case over.
6. Heat sleeve (4) to a temperature of 135°C (275°F) and install the sleeve in the clutch and gear assembly.
7. Install bearings (5) on the sleeve.
8. Install thrust disc (7) and washer (6).
9. Heat bearing (8) to a temperature of 135°C (275°F) and install it over the shaft. Install spacer (9).
10. Install bearing race (10) in the transfer gear case.
11. Install shims (11). See the topic "Transfer Box Drive Shaft End Play" in Specifications manual, Form No. SENR5804.
12. Install lock (13) and nut (12). Do not bend the tab on the lock and only tighten the nut finger tight.
13. Install spacer (15), the gasket and cover (14). Tighten the bolts for the cover only finger tight.
14. Turn the transfer case over.
15. Install bearing race (16) over the bearing.
16. Install the O-ring seal in groove (17).
17. Install lip-type seal (18) in the adapter with the lip toward the yoke.
18. Install the spool and spring and tighten bolt (19) to a torque of 34 to 54 N·m (25 to 40 lb ft).
19. Put 7M7260 Liquid Gasket on adapter (21). Install O-ring seals (20) on the adapter. Install adapter (21) on the transfer gear case.
20. Put 5P3413 Thread Sealant on bolts (26) and install them to hold the adapter. Tighten the bolts to a torque of 45 to 64 N·m (33 to 47 lb ft).
21. Install yoke (24). Install O-ring seal (25), spacer (24), the lock and bolt (22). Tighten the bolt to a torque of 68 to 88 N·m (50 to 65 lb ft).
22. Bend the tab on the lock to hold the bolt.
23. Remove gasket (27) and cover (14). Tighten nut (12) to a torque of 54 to 82 N·m (40 to 60 lb ft). Install gasket (27) and cover (14). Install the bolts that hold the cover to a torque of 45 to 64 N·m (33 to 47 lb ft). Bend the tab on the lock to hold the nut. See the topic "Transfer Box Drive Gear Mesh At Installation" in Specifications manual, Form No. SENR5804.
End By:
a. install front drive transfer gear box