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Input shaft disassembly
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TM-5-4210-229-14P Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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Clutch gear and bearing assembly
TM5-4210-229-14&P 6-18. TRANSFER CASE REPAIR (Continued). h. Front output shaft removal. (1)   Remove the seal carrier (42) from the front of the case and the cap (43) from the rear of  the case. Drive the shaft from the rear of the case until the front bearing (44) is clear of the housing.  Use a bearing  puller  between  the  bearing  and  the  case to remove the bearing from the shaft.  The shaft and gear assembly can now be removed. (2)   Remove the shaft from the gear in an arbor press. REPAIR a. Parts cleaning. Cleaning   solvent   (Appendix   D,      Item   54)   is both toxic and flammable.  Keep off skin.  Use only    in    a    well    ventilated    are    and    avoid prolonged  breathing  of  vapors.    Keep  away from open flames. (1)   Clean  all  components  with  solvent  (Appendix  D, Item 54). Compressed  air  used  for  cleaning  or  drying can  create  airborne  particles  that  may  enter the  eyes.    Pressure  shall  not  exceed  30  psi (206 kPa).  Wearing of goggles is required to avoid injury to personnel. (2)   Dry all parts after cleaning with a clean,  soft shop towel  (Appendix  D,    Item  55).    Compressed  air can  be  used  to  dry  in  accessible  areas  of  large parts.  Compressed air should not be used to spin dry  bearings.    Spin  dry-ing  bearings  may  cause damage  to  the  mat-ing  surfaces  due  to  lack  of lubrication. (3)   To    prevent    corrosion    damage,        dried    parts should   be   immediately   coated   with   a   light   oil (Appendix D,  Item 37). b. Inspection. (1)   Carefully inspect all parts being reused for signs of    wear    or    damage.        Examine    all    bearing surfaces,      ball   bearing   assemblies   and   roller bearing   cups   and   cones   for   wear,      pitting   or overheating.    Examine  gears  for  pitting,  scoring and  broken  teeth.    Shafts  should  be  examined for nicks,  mars,  and damaged threads.  Check all   shift   forks   and   slots   in   sliding   clutches   for extreme  wear  or  discoloration  from  heat.    Also check    the    teeth    engagement    of    the    sliding clutches for partial engagement pattern. Discrepant  parts  or  any  part  showing  signs  of wear or damages should be repaired or replaced. ASSEMBLY NOTE All parts must be clean and all gasket surfaces must be free of old gasket material. In   order   to   reduce   chances   of   galling   or scoring  and  to  provide  initial  lubrication  for the oil seals,  lubricate housing bores,  shaft splines and-bearing mounting surfaces,  and sealing   lips   on   oil   seals   with    Lubriplate (Appendix D,  Item 34)or equal. When  installing  bearings,    use  flanged  end bearing drivers that will apply equal force to both inner and outer races of the bearings.  If tubular    or    sleeve    type    drivers    are    used, apply  the  force  to  either  the  inner  or  outer race   or   both   races   as   needed   to   put   the bearing in place without pushing through the bearing balls. 6-98

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