Transfer Gearbox - Disassemble
Disassembly Procedure
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| Required Tools | |||
| Tools | Part Number | Description | Qty |
| A | 126-7181 | Sliding Plate | 1 |
| 6V-3009 | Crossbar | 1 | |
| 1A-2701 | Screw | 1 | |
| 8C-2926 | Bolt | 1 | |
| B | 8B-7551 | Bearing Puller | 1 |
| C | 163-2402 | Spanner Wrench | 1 |
| D | 7F-1929 | Spanner Wrench | 1 |
| E | 1P-1861 | Retaining Ring Pliers | 1 |
| F | 8T-5096 | Dial Indicator Group | 1 |
Start By:
- Remove the transfer gearbox. Refer to Disassembly and Assembly, "Transfer Gearbox - Remove".
- Remove cotter pin (1) .
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| Illustration 1 | g00611622 |
- Remove the nut and washer (2) .
- Use Tooling (A) to remove pulley (3). The weight of the pulley is 34 kg (75 lb).
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| Illustration 2 | g00611624 |
- Remove key (4) .
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| Illustration 3 | g00611626 |
- Remove twelve bolts (5) and housing (6) from the transfer gearbox.
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| Illustration 4 | g00611628 |
- Remove bearing cup (7), lip seal (8), and gasket (9) from housing (6) .
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| Illustration 5 | g00611631 |
- Remove the drive shaft and gear assembly (10) .
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| Illustration 6 | g00611634 |
- Place the drive shaft, the gear assembly, and Tooling (B) into a suitable press, as shown. Remove bearing cone (12) from shaft (11) .
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| Illustration 7 | g00611637 |
- Reposition the shaft and the gear assembly in a suitable press, as shown. Remove bearing cone (12), the centering ring, and gear (14) .
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| Illustration 8 | g00611640 |
- Use Tooling (C) to remove cover (15) .
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| Illustration 9 | g00611642 |
- Remove lip seal (16) and O-ring (17) from the cover.
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| Illustration 10 | g00611648 |
- Remove bearing cup (18) from housing (19) .
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| Illustration 11 | g00611650 |
- Straighten the tab on locking plate (20). Use Tooling (D) to remove the nut.
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| Illustration 12 | g00611652 |
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| Illustration 13 | g00611655 |
- Use a brass drift to remove intermediate shaft (21), bearing cone (22), bearing cone (28), and the gear assembly.
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| Illustration 14 | g00611660 |
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| Illustration 15 | g00611664 |
- Remove bearing cups (23) and (27) from gear (25). Use Tooling (E) to remove retaining rings (24) and (26) from gear (25) .
- Remove O-rings (29) and (30) from intermediate shaft (21) .
- Remove six bolts (31) and remove bearing cover (32) .
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| Illustration 16 | g00611668 |
- Remove gasket (33) and bearing cup (34) from bearing cover (32) .
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| Illustration 17 | g00611682 |
- Remove gear assembly (35) from the gearbox housing.
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| Illustration 18 | g00611687 |
- Remove bearing cup (36) from gearbox housing (19) .
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| Illustration 19 | g00611696 |
- Place spur gear (39) and Tooling (B) in a suitable press, as shown. Remove bearing cone (38) from the spur gear.
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| Illustration 20 | g00611700 |
- Reposition spur gear (39) and Tooling (B) in a suitable press, as shown. Remove bearing cone (38) from spur gear (39) .
- Use Tooling (C) to remove cover (40) from gearbox housing (19) .
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| Illustration 21 | g00611703 |
- Remove plate (41) for the oil feed from gearbox housing (19) .
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