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REPAIR - TM-5-4210-229-14P_491
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TM-5-4210-229-14P Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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Rear output shaft assembly.
TM5-4210-229-14&P 6-18. TRANSFER CASE REPAIR (Continued). NOTE Utilizing guide studs will simplify the installation of gaskets,  bearing carriers,  seal carriers and caps. Before  installation,    universal  joint  yokes  or companion   flanges   should   be   coated   with Lubriplate (Appendix D,  Item 34) on the seal operating area.  They should be  torqued into place with the locknuts torqued to the proper specified torque before the cover is installed on the case and before the shim thickness is determined  for  both  the  input  shaft  and  the rear output shaft.  The retaining nuts for the universal joint yoke or companion flange can be torqued or loosened most easily when all components,  except  shift  forks  are  in  place. At that time,  it is impossible to engage both the   direct   drive   and   the   underdrive   clutch gears  and  effectively  lock  all  shafts  against rotation. Seal  bolt  threads  with  sealant  (Appendix  D, Item 47) or equal pliable setting sealant.  Bolt threads that are not sealed will leak oil. Replacement     seals     are     coated     (on     the outside)  and  should  not  be  coated  prior  to their  installation  into  the  carriers,    however, they should be coated on the sealing lip with Lubriplate   (Appendix   D,      Item   34).      Seal installation  can  best  be  made  with  an  arbor press. a. Clutch gear and bearing assembly. Apply  Lubriplate  (Appendix  D,    Item  34)  to  the bearing   bores   of   each   of   the   three   clutching gears.  Press the bearings into place by applying a  force  to  the  outer  race.    Be  sure  to  put  the applicable spacer rings(88 and 49) in place prior to the installation of the second bearing in the 35 tooth clutch-ing gears (18 and 48). b. Front output shaft assembly. (1)   Insert  the  plain  end  of  the  shaft  (46)  into  the clutch gear assembly (47,  48,  and 49).  Install spacer  ring  (50)  and  the  ring  bearing  (51)  onto the  shaft  (46).    Slide  the  clutch  (45)  onto  the splined end of the shaft (46).  Engage the teeth of the clutch (45) with the teeth in the clutch gear (48).  Put this assembly into the case through the cover opening with the gear at the opposite side of   the   housing   from   the   front   output   opening. Put  the  threaded  end  of  the  shaft  into  the  front output  opening  and  swing  the  gear  end  partially into the intermediate shaft rear opening to allow the  opposite  end  of  the  shaft  to  enter  the  front output   opening.      Slide   shaft   through   the   front output   opening   enough   to   allow   backing   the bearing into the rear case bearing bore. 6-99

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