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TM-5-4210-229-14P Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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Intermediate shaft assembly
TM5-4210-229-14&P 6-18. TRANSFER CASE REPAIR (Continued). (2)   Slip  the  front  bearing  (44)  over  the  end  of  the shaft   and   into   the   housing   bore.      The   bearing snapring  should  be  on  the  outboard  side  of  the bearing.  Tap bearing into place. (3)   Install the front output seal carrier gasket (52) and the  seal  carrier  (42)  with  the  seal  (53)  in  place. Apply   sealant   (Appendix   D,   Item   47)   to   bolt threads,    then  torque  bolts(54)  to  45  ft-lb  (61.02 N.m). (4)   Coat the seal surface and the  splined hole of the front   output   yoke   with   Lubriplate   (Appendix   D, Item 34). (5)   Align the yoke onto the shaft and tap it into place. Lightly coat one side of the yoke retaining washer (55) with sealant (Appendix D,  Item 47) and then install the coated side next to the yoke.  Install the locknut   (56)   and   torque   it   to   300   ft-lb   (406.80 N.m). (6)   Temporarily   install   the   rear   cap   (43)   in   place without  shims  (57).    Torque  bolts  (58)  to  25  ft-lb (33.80   N.m).      Measure   gap   between   the   case housing and the flange of the cap (43).  Select a shim  stack  that  is  0.010  to  0.15  inch  larger  than the gap dimensions measured.  Remove the bolts (58)  and  cap  (43)  and  then  install  the  selected shims  and  reinstall  the  cap.    Coat  bolt  threads with  sealant  (Appendix  D,    Item47),    install  and torque bolts (58) to 45 ft-lb (61.02 N.m). (7)   Make certain the bearings are pulled tight against the   shaft   shoulders   and   that   the   shaft   rotates freely,  do this by spinning the shaft. c. Rear output shaft assembly. (1)  Install  the  split  retaining  ring  (41)  onto  the  shaft (59).  (If removed at disassembly). (2) Press  the  front  bearing  cone  (60)  tight  against  the shaft shoulder and then install the washer (61) and locknut (62).  Torque the locknut to 300 ft-lb (406.80 N.m). (3) Coat    the    splined    bore    of    the    gear    (38)    with Lubriplate (Appendix D,  Item 34). (4) Lower  the  rear  output  gear  (38)  into  the  case  with the  flat  face  against  the  back  wall  of  the  case  and the chamfered side toward the front of the case. (5) Coat the shaft  splines with  Lubriplate (Appendix D, Item 34). (6) Insert the shaft through the proper hole in the front of the case and align the shaft splines with the gear splines.  Protect the threaded end of the shaft and tap  the  shaft  into  the  gear  until  the  retaining  ring seats in the chamfer of the gear. (7) Install the spacer ring (39). Use   heat-resistant   gloves   when   working   with   high temperatures. (8)  eat the rear bearing cone (40) to approximately 250° (121°  C).  Handle bearing with heat resistant gloves and install quickly after heating,  tapping it into place if necessary. (9)     Install the spacer tube (63) onto the shaft (59). (10)   Move   the   shaft   toward   the   front   of   the   case   to visually inspect the mating parts. (11)   Install   the   front   bearing   cup   (37)   and   the   rear bearing  cup  (64)  allowing  the  rear  cup  to  remain projecting  between  3/8  inch  and1/4  inch  from  the case. (12)  Install  the  rear  output  carrier  gasket  (65)  and  the rear  output  carrier  (36)  along  with  seal  (66).    Coat retaining bolt threads in sealant (Appendix D,  Item 47),    install  and  torque  bolts  (67)  to  45  ft-lb  (61.02 N.m). 6-100

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