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Rear output shaft assembly.
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TM-5-4210-229-14P Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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Input shaft assembly
TM5-4210-229-14&P 6-18. TRANSFER CASE REPAIR (Continued). (13) Coat   the   seal   surface   and   the   splined hole of the rear output companion flange with Lubriplate (Appendix D,  Item 34),  then install flange.  Lightly coat one side of the retaining washer     (68)     with     sealant     (Appendix     D, Item47) and then install the coated side next to  the  companion  flange.    Install  the  locknut (69) and torque it to 300 ft-lb (406.80 N.m). (14) Temporarily  install  the  rear  output  shaft  front cover (35) without shims (70) and torque bolts (71) to 25 ft-lb (33.90 N.m).  Measure the gap between the cover (35) and the case housing. Select a shim stack that is 0.010 to 0.005 inch larger   than   the   gap      dimension   measured. Remove  the bolts (71) and the cap (35) and then install he selected shims and reinstall the cap.      Coat   the   bolt   threads   with   sealant (Appendix  D,    Item  47),    install  and  torque bolts (7 1) to 45 ft-lb (61.02 N.m). d. Intermediate shaft assembly. (1) Install the double row ball bearing (72) in the housing  bore  opposite  the  large  opening  at the  rear  of  the  case.    Temporarily  retain  the bearing with a bolt and washer. (2) Insert  the  alignment  tool  through  the  bearing with  the  tapped  end  toward  the  inside  of  the case. (3)   Put  the  bearing  spacer  washer  (34)  in  place onto  the  alignment  tool  on  the  inside  of  the case.    Place  the   underdrive  driven  gear  (32) and  bearing  assembly  (33)  on  the  alignment tool.      Insert   the   sliding   clutch   (73)   into   the engaged  position  inside  the  underdrive  driven gear (32). (4)   Install   the   split   retaining   ring   (74)   into   the groove on the intermediate shaft (75). (5)   Insert  the  shaft  through  the  large  opening  on the  back  of  the  case.    Align  shaft  with  clutch splines  and  engage  the  end  of  the  shaft  with alignment   tool.      Screw   the   tool   and   shaft together  and  then  pull  the  shaft  through  the bearings.    Once  the  shaft  is  pulled  through, remove  the  alignment  tool.    Install  the  spacer tube (30),  speedometer(29),  and locknut (28) on   the   end   where   the   alignment   tool   was removed. (6)   Put  the  direct  drive  gear  (76)  onto  the  shaft with the chamfered spline side toward the front of the case so the chamfer will fit upon to the split retaining ring (74). (7)   Install  the  spacer  washer  (77)  and  the  roller bearing  inner  race  (3  1)  on  the  shaft.    Make sure  the  shoulder  on  the  race  is  toward  the gear  to  allow  the  cover  and  the  bearing  outer race  and  roller  assembly  to  fit  over  the  inner race. (8)   Install  the  retaining  washer  (78)  and  lock-nut (79)  on  the  shaft.    Torque  the  nut  (28)  on  the speedometer   gear   end   to   175   ft-lb   (237.30 N.m) while restraining the nut on the opposite end of the shaft. (9)   Torque    the    rear    locknut    (79)    to    300    ft-lb (406.80 N.m) while restraining the front output yoke from turning. 6-101

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