Usage:
Remove Transfer Gears
start by:
a) remove transmission and transfer gears
b) remove governor drive group
1. Remove three bolts (2) and lockwashers. Remove filter housing (1) from the transfer gear case.
2. Remove transmission governor drive shaft (3) from the transfer gears and transmission.
3. Install 5/8"-11 NC forged eyebolt (4) on the transfer gear case and fasten a hoist as shown. Remove bolts (5) and lockwashers that fasten the transfer gear case to the transmission.
4. Use two 1/2"-13 NC forcing screws (6) and (7) to make a separation of the transfer gears and the transmission. Remove the transfer gears. The weight of the transfer gears is 350 lb. (158 kg).
Install Transfer Gears
1. Inspect the condition of all O-ring seals and make replacements if necessary.
2. Install eight O-ring seals (1), (2) and (4) on the transmission. Install two 1/2"-13 NC guide pins (3) on the transmission as shown.
3. Install a 5/8"-11 NC forged eyebolt on the transfer gear case and fasten a hoist as shown. Put transfer gear assembly (5) in position on the transmission. Be sure the splines on the transmission input shaft are in alignment with the splines in the transfer gear. Install the bolts and lockwashers that fasten the transfer gear case to the transmission.
4. Put transmission governor drive shaft (6) in position in the transmission and transfer gears.
5. Put O-ring seal (7) in position on filter housing (8). Install the filter housing on the transfer gear case with three bolts and lockwashers.
end by:
a) install governor drive group
b) install transmission and transfer gears
Disassemble Transfer Gears
start by:
a) remove transfer gears
1. Remove yoke (1) from the transfer gear assembly.
2. Use tooling (A) to remove bearing (2) from the transfer gear case.
3. Remove the bolts and lockwashers that fasten cage (3) to the case. Use two 3/8"-16 NC forcing screws (4) to make a separation of the cage and case. Remove the cage and shims from the case.
4. Remove lip type seal (5) from the cage with tooling (B).
5. Use tooling (C) as shown to remove bearing cup (6) from cage (3). Remove O-ring seal (7) from the cage.
6. Remove gear (8) from the case.
7. Use tooling (D) as shown to remove two bearing cones (9) from gear (8).
8. Use tooling (E) as shown to remove bearing cup (11) from the case. Disconnect and remove tube (10) from the case.
9. Remove the bolts and lockwashers that fasten cage (13) to the case. Use two 3/8"-16 NC forcing screws (12) to make a separation of the cage and case. Remove the cage and shims from the case.
10. Use tool (F) and a press to remove the bearing cup from cage (13).
11. Remove gear (14) from the case.
12. Use tooling (G) as shown to remove two bearings (15) from gear (14).
13. Use tooling (H) as shown to remove bearing cup (16) from the case.
Assemble Transfer Gears
1. Make sure all parts of the transfer gear group are clean and free of dirt and foreign material.
2. Lower the temperature of bearing cup (1) and install in the transfer gear case until the cup makes contact with the bottom of the bore.
3. Heat two bearings (2) to 275°F (135°C) and install on gear (3) until the bearing makes contact with the shoulders on the gear.
4. Install gear assembly (3) in the transfer gear case.
5. Use a press and tool (A) to install the bearing cup in cage (4). Install the cup until it makes contact with the bottom of the bore.
6. Install cage (4) and shims on the case with bolts (5) and lockwashers. Use tooling (B) as shown to measure the end play of gear (3). Remove or install shims between the cage and case to get an end play measurement of .006 ± .002 in. (0.15 ± 0.05 mm).
7. Lower the temperature of bearing cup (6) and install in the case until the cup makes contact with the bottom of the bore.
8. Heat two bearings (7) to 275°F (135°C) and install on gear (8) until the bearing makes contact with the shoulder on the gear.
9. Install gear assembly (8) in the case.
10. Use tooling (C) to install the lip type seal in cage (9). Install the seal with the seal lip toward the inside of the cage. Install the seal until it makes contact with the bottom of the bore in the cage. Put a thin layer of SAE 30 oil on the seal lip.
11. Lower the temperature of bearing cup (10) and install in cage (9) until the cup makes contact with the bottom of the bore in the cage.
12. Install O-ring seal (11) on the cage. Put a thin layer of SAE 30 oil on the O-ring seal. Install the cage and shims (12) on the case. Install the bolts and lockwashers that fasten the cage to the case.
13. Use tooling (B) as shown to measure the end play of gear (8). Remove or install shims (12) between the cage and the case to get an end play measurement of .006 ± .002 in. (0.15 ± 0.05 mm).
14. Install the governor drive bearing in the case with tooling (D). Install the bearing until it is .050 in. (1.27 mm) below the surface of the case.
15. Install yoke (13) in the case.
end by:
a) install transfer gears