Output Transfer Gears - Disassemble
Disassembly Procedure
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| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 6V-2156 | Link Bracket | 2 |
| B | N/A | 3/8-16 NC X 3" Bolt | 2 |
| C | 5P-5197 | Retaining Ring Pliers | 1 |
| D | 1P-0510 | Driver Group | 1 |
| E | 5P-4758 | Retaining Ring Pliers | 1 |
| F | 8B-7548 | Push Puller Tool | 1 |
| 5F-7343 | Puller Assembly | 1 | |
| G | 8B-7554 | Block | 4 |
| 6V-3009 | Crossblock | 1 | |
| N/A | 1/2-13 X 10" Rods with Nuts and Washers | 2 | |
| H | 5P-4184 | Puller Stud | 1 |
| 6V-3175 | Cylinder Group | 1 | |
| FT-2549 | Receiver | 1 | |
| 9U-6832 | Fast Runner Nut Assembly | 1 | |
| 9U-6600 | Hydraulic Hand Pump | 1 | |
Start By:
- Remove the housing for the transmission speed sensor. See Disassembly and Assembly, "Speed Sensor (Transmission) - Remove and Install".
- Separate the output transfer gears from the transmission. See Disassembly and Assembly, "Transmission and Transfer Gears - Separate".
Note: There are two different types of idler gears and shafts that can be used: splined and press fit
- Remove bolt (1) and the washer from the rear yoke of the output transfer drive.
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| Illustration 1 | g00517791 |
- Fasten Tooling (A) and a hoist to the yoke for the interaxle differential. It may be necessary to use Tooling (B) in order to assist in forcing the interaxle differential assembly from the housing. Disconnect the wiring from the output transfer gear housing. Remove eleven bolts (2) and the washers. Remove the interaxle differential assembly from the output transfer gear housing. The weight of the interaxle differential assembly is 84 kg (185 lb).
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| Illustration 2 | g00517823 |
- Flip the output transfer drive. Remove six bolts (3) and the washers that hold the output yoke flange assembly to the output transfer gear housing. It might be necessary to use Tooling (B) in order to assist in forcing the output yoke flange assembly from the housing. Remove the output yoke flange assembly and any shim pack from the housing.
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| Illustration 3 | g00517841 |
- Remove retainer ring (4) from the output yoke flange assembly with Tooling (C) .
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| Illustration 4 | g00517848 |
- Position the output yoke flange assembly in a press as the picture shows. Push yoke (6) from the flange assembly (5) with a press and Tooling (D) .
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| Illustration 5 | g00517849 |
- Remove thrust washer (7) and O-ring (8) from flange assembly (5) .
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| Illustration 6 | g00518022 |
- Remove retainer ring (9) with Tooling (E) . Remove roller bearing (10) from the output flange.
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| Illustration 7 | g00518058 |
- Use a press and Tooling (D) in order to press the seal out of the flange assembly. The seal is not visible in the picture.
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| Illustration 8 | g00518061 |
- Remove six bolts (11) from brake housing (12) . Loosen two opposite bolts at a time. Remove two opposite bolts at a time.
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| Illustration 9 | g00518063 |
- Attach Tooling (A) to brake housing (12) . It may be necessary to use Tooling (B) in order to assist in forcing the brake housing from the output transfer gear housing. Attach the brake housing to a suitable lifting device and remove the brake housing from the output transfer drive. The weight of the brake housing assembly is 68 kg (150 lb).
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| Illustration 10 | g00518065 |
- Loosen six bolts (13) from brake housing (14) . Loosen two opposite bolts at a time. Remove two opposite bolts at a time.
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| Illustration 11 | g00518066 |
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Sudden release of spring force can cause injury. To prevent the possibility of injury, follow the procedure to relieve the spring pressure. |
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- Flip the cover plate. Use Tooling (C) in order to remove retainer ring (15) .
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| Illustration 12 | g00518074 |
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| Illustration 13 | g00518077 |
Note: Note the proper orientation of the springs.
- Remove four springs (16) .
- Remove O-ring (17) and plate (18) . Remove nine discs and eight friction discs (19) .
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| Illustration 14 | g00518122 |
- Remove piston (20) and reaction plate (21) .
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| Illustration 15 | g00518127 |
- Check the condition of the interior seal (23) and exterior seal (22) on the piston. Replace the seals if it is necessary.
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| Illustration 16 | g00518128 |
- Attach input gear (24) to a suitable lifting device. Lift input gear (24) out of the output transfer gear housing. The weight of the input gear is 34 kg (75 lb).
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| Illustration 17 | g00518129 |
- Use Tooling (F) in order to remove bearing (25) from the input gear. Repeat this procedure for the bearing on the other side.
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| Illustration 18 | g00518141 |
- Use Tooling (H) in order to pull the idler gear shaft (26) . Remove idler gear shaft (26) from the output transfer gear housing.
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| Illustration 19 | g00518142 |
- Use Tooling (D) and a press to remove bearing (27) from idler gear shaft (26) .
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| Illustration 20 | g00518143 |
- Remove idler gear (28) from the output transfer gear housing.
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| Illustration 21 | g00518144 |
- Remove bearing (29) from the output transfer gear housing.
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| Illustration 22 | g00518146 |
- Remove bearing races (30) from the output transfer gear housing.
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| Illustration 23 | g00518147 |
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