Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | 1P-0520 | Driver Gp | 1 |
C | 138-7573 | Link Bracket | 2 |
K | - | Loctite Hi-Temp Flange Sealant | - |
L | - | Loctite 592 | - |
M | 8T-5096 | Dial Indicator Gp | 1 |
Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected at all times.
NOTICE |
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Failure to properly assemble parts or failure to follow established procedures can lead to damage of the parts and assembly. To avoid damage to parts, always identify and mark the parts so that they can be installed in the same location. Ensure that gear surfaces align. Never force parts during assembly. |
- Lower the temperature of bearing cups (49) and (50). Install bearing cups (49) and (50) to the transfer gear case.
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Illustration 2 g01061264 - Raise the temperature of two bearing cones (51). Install bearing cones (51) to gear (48).
- Lubricate two bearing cones (51) with the lubricant that is being sealed.
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Illustration 3 g01061265 - Attach a suitable lifting device to gear (48). The weight of gear (48) is approximately
29 kg (64 lb) . Install gear (48) to transfer gear case (7).Show/hide tableIllustration 4 g01061266 - Raise the temperature of two bearing cones (47). Install bearing cones (47) to gear (46).
- Lubricate two bearing cones (47) with the lubricant that is being sealed.
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Illustration 5 g01061267 - Attach a suitable lifting device to gear (46). The weight of gear (46) is approximately
39 kg (86 lb) . Install gear (46) to transfer gear case (7).Show/hide tableIllustration 6 g01061268 Show/hide tableIllustration 7 g03706396 - Install speed sensor (45) to transfer gear case (7).
- Install speed sensor (44) to transfer gear case (if equipped).
- Set the clearance (X) between sensor (45) and gear (48) to
0.71 mm (0.028 inch) . Tighten nut (52) to a torque of25 ± 5 N·m (18 ± 4 lb ft) . - Repeat Step 10 for speed sensor (44) (if equipped).
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Illustration 8 g01061699 - Apply Tooling (K) to the mating surface of the transfer gear case and of gear case cover (27).
- Install Tooling (C) and a suitable lifting device to gear case cover (27). The weight of gear case cover (27) is approximately
45 kg (100 lb) . Install gear case cover (27) to the transfer gear case.Show/hide tableIllustration 9 g01061248 - Install eight bolts (43) to gear case cover (27). Tighten bolts (43) to a torque of
135 ± 20 N·m (100 ± 15 lb ft) .Show/hide tableIllustration 10 g01061247 - Install drain assembly (42) and bolts (41) to transfer gear case (7).
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Illustration 11 g01094884 - Lower the temperature of bearing cup (40). Install bearing cup (40) to bearing cage (35).
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Illustration 12 g01094885 - Lower the temperature of bearing cup (32). Install bearing cup (32) to bearing cage (30).
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Illustration 13 g01094886 - Install O-ring seal (36) to bearing cage (35).
- Install cover (34) to bearing cage (35).
- Install the four nuts (not shown) to cover (34).
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Illustration 14 g01084241 - Install bearing cage (30) and bearing cage (35) to gear case cover (27).
Note: Do not install the O-ring seal to bearing cage (35) or shims (31) (not shown) and (38) (not shown) at this time.
- Install two bolts (29), 180° apart to bearing cage (30).
- Install two bolts (37), 180° apart to bearing cage (35).
- Tighten bolts (29) and (37) evenly to a torque of
20.3 N·m (180 lb in) . - Rotate gear (48) approximately 30° for three or four times. Tighten bolts (29) and (37) evenly to a torque of
40.7 N·m (360 lb in) . - Rotate gear (48) approximately 30° for three or four times. Without moving gear (48), loosen bolts (29) and (37).
- Tighten bolts (29) and (37) evenly until finger tight.
- Tighten bolts (29) and (37) evenly to a torque of
20.3 N·m (180 lb in) . - Rotate gear (48) approximately 30° for three or four times. Tighten bolts (29) and (37) evenly to a torque of
20.3 N·m (180 lb in) . - Repeat Step 29 until bolts (29) and (37) do not move at a torque of
20.3 N·m (180 lb in) .Note: Steps 31 through 33, are used for the gap at bearing cage (30).
- Measure the gap between gear case cover (27) and bearing cage (30). Measure the gap at each bolt. Measure the gap between the bearing cage and the housing from the center of the bolt to the outside diameter of the bearing cage flange.
- Add the two measurements together. Divide the sum by two to determine the average gap measurement between gear case cover (27) and bearing cage (30).
- Add
0.41 mm (0.016 inch) to the average gap measurement in order to determine the thickness of the shims required for bearing cage (30).Note: Steps 34 through 36, are used for the gap at bearing cage (35).
- Measure the gap between gear case cover (27) and bearing cage (35). Measure the gap at each bolt. Measure the gap between the bearing cage and the housing from the center of the bolt to the outside diameter of the bearing cage flange.
- Add the two measurements together. Divide the sum by two to determine the average gap measurement between gear case cover (27) and bearing cage (35).
- Add
0.46 mm (0.018 inch) to the average gap measurement in order to determine the thickness of the shims required for bearing cage (35). - Assemble shim packs (31) (not shown) and shim pack (38) (not shown) in order to match the thickness determined in Step 33 and Step 36.
- Remove bearing cages (30) and (35).
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Illustration 15 g01640794 - Install shim pack (38) (not shown) and bearing cage (35) to gear case cover (27).
- Install seven bolts (37) to bearing cage (35). Tighten bolts (37) to a torque of
135 ± 20 N·m (100 ± 15 lb ft) . - Remove cover (34).
- Use tooling (M) in order to ensure that end play is present at gear (46). Add or remove shims that were installed in Step 39 to achieve
0.05 + 0.05 - 0.03 mm (0.002 + 0.002 - 0.001 inch) end play. - Remove bearing cage (35).
- Install O-ring seal (39) (not shown) to bearing cage (35).
- Install bearing cage (35). Tighten bolts (37) to a torque of
135 ± 20 N·m (100 ± 15 lb ft) . - Install cover (34).
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Illustration 16 g01061246 - Install shim pack (31) (not shown) and bearing cage (30) to gear case cover (27).
- Install eight bolts (29) to bearing cage (30). Tighten bolts (29) to a torque of
135 ± 20 N·m (100 ± 15 lb ft) . - Use tooling (M) in order to ensure that end play is present at gear (48). Add or remove shims that were installed in Step 47 to achieve
0.05 ± 0.03 mm (0.0020 ± 0.0012 inch) end play.Show/hide tableIllustration 17 g01094139 - Install O-ring seal (28) to cover (26).
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Illustration 18 g01061245 - Install cover (26) and nine bolts (25) to gear case cover (27).
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Illustration 19 g01094887 - Raise the temperature of bearing (24). Install bearing (24) to shaft (18).
- Lubricate bearing (24) with the lubricant that is being sealed.
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Illustration 20 g01094888 Show/hide tableIllustration 21 g01094135 - Lower the temperature of the two bearing cups. Install one bearing cup to bearing cage (16).
- Lubricate two bearing cones (23) with the lubricant that is being sealed.
- Install two bearing cones (23) to bearing cage (16).
- Install the second bearing cup to bearing cage (16).
- Install retainer (22) and six bolts (21) to bearing cage (16).
Note: The part number on retainer (22) should be visible.
Show/hide tableIllustration 22 g01094890 - Apply Tooling (L) to the outer edge of lip seal (20) (not shown) prior to installation.
- Use Tooling (A) in order to install lip seal (20) to bearing cage (16).
Note: The lip of lip seal (20) must face toward the inside of bearing cage (16).
Note: Lip seal (20) must contact the counterbore in bearing cage (16).
Show/hide tableIllustration 23 g01094891 - Position bearing cage (16), the spacer, and gear (19) in a suitable press. Install shaft (18) through gear (19), the spacer, and bearing cage (16).
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Illustration 24 g01094132 Show/hide tableIllustration 25 g01094131 - Install O-ring seal (17) to bearing cage (16).
- Install Tooling (C) and a suitable lifting device to bearing cage (16). The weight of bearing cage (16) is approximately
95 kg (210 lb) . Install bearing cage assembly (16) to transfer gear case (7).Show/hide tableIllustration 26 g01094126 - Install 11 bolts (15) to bearing cage (16). Tighten bolts (15) to a torque of
135 ± 20 N·m (100 ± 15 lb ft) .Show/hide tableIllustration 27 g01094125 - Install yoke (13) and O-ring seal (14).
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Illustration 28 g01094123 - Install retainer (12) and bolt (11) to yoke (13). Tighten bolt (11) to a torque of
480 ± 52 N·m (355 ± 40 lb ft) .Show/hide tableIllustration 29 g01094892 - Lower the temperature of bearing cup (9). Install bearing cup (9) to bearing cage (6).
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Illustration 30 g01094893 - Install O-ring seal (10) to bearing cage (6).
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Illustration 31 g01094894 - Apply Tooling (L) to the outer edge of lip seal (8) (not shown) prior to installation.
- Use Tooling (A) in order to install lip seal (8) to bearing cage (6).
Note: Lip seal (8) must contact the counterbore in bearing cage (6). The lip of seal (8) must face toward the inside of bearing cage (6).
Show/hide tableIllustration 32 g01094117 - Turn the transfer gear case. The weight of the transfer gear case is approximately
520 kg (1150 lb) . - Install bearing cage (6) to the transfer gear case.
- Install eight bolts (5) to bearing cage (6). Tighten bolts (5) to a torque of
55 ± 10 N·m (40 ± 7 lb ft) .Show/hide tableIllustration 33 g01094116 - Install yoke (3) and O-ring seal (4).
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Illustration 34 g01094114 - Install retainer (2) and bolt (1) to yoke (3). Tighten bolt (1) to a torque of
480 ± 52 N·m (355 ± 40 lb ft) .
Illustration 1 | g01061263 |
End By:
- Connect the output transfer gears to the transmission. Refer to Disassembly and Assembly, "Transmission to Output Transfer Gears - Connect".