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Intermediate shaft assembly
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TM-5-4210-229-14P Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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Shifter shafts assembly.
TM5-4210-229-14&P 6-18. TRANSFER CASE REPAIR (Continued). (10) Install the intermediate shaft rear cover gasket (80)   and   cover   (27)   utilizing   guide   studs   to simplify   installation.      Coat   bolt   threads   with sealant  (Appendix  D,    Item  47),    install  and torque bolts (8 1) to 45 ft-lbs (61.02 N.m).  (No end play adjustment is required.) (11) Remove the bolt and washer that was used to temporarily  retain  the  bearing  (72).    Position the speedometer cap gasket (82) over the front of  the  shaft.    make  sure  the  oil  return  hole  in the gasket is aligned with the hole in the case. (12) Place the speedometer cap (26) in place along with the speedometer cable.  Coat bolt threads with sealant (Appendix D, Item 47),  install and torque bolts (83) to45 ft-lb (61.02 N.m). (13) Install   the   speedometer   driven   gear   (84)and speedometer    driven    gear    connector    sleeve (85)     into     the     speedometer     cap     (26).The speedometer    driven    gear    connector    sleeve (85)  should  have  been  capped  with  a  plastic cap   (86)   when   the   speedometer   cable   was removed  in  order  to  keep  speedometer  gear clean. (14) Install vent (87) in the speedometer cap (26). e. Input shaft assembly. (1) Place  the  direct  drive  gear  (18)  with  bearings (22) and spacer (88) already installed, into the housing   against   the   back   wall.      The   gear should mesh with the gear on the inter-mediate shaft and rest against the side wall of the case housing. (2) Insert   the   direct   drive   gear   clutch   (24)   into   the direct drive gear (18). (3) From  the  front  of  the  case,    insert  the  end  of  the shaft  (89)  that  is  not  threaded.    The  shaft  should project    into    the    case    between3/4    inch    and    2 inches. (4) Slip   the   underdrive    pinion    gear    (19)    with    the projecting  face  toward  the  shaft,    onto  the  end  of the shaft. (5) Slide  the  shaft  (89)  through  the  underdrive  pinon gear  (19)  and  into  the  direct  drive  sliding  clutch (24).      Align   the    splines   when   they   come   into contact   with   the   pinion   gear.      Continue   shaft installation,    align  the   splines  with  splines  in  the underdrive  gear  sliding  clutch  (18).    Continue  to slide  shaft  into  place  through  bearings  (22)  and gear(18).      Slip   the   spacer   washer   (25)   (.06   in. thick) over the rear end of the shaft. (6)     Slide  the  input  shaft  front  bearing  (21)  and  rear bearing   (23)   onto   the   shaft.      Using   a   suitable driver,    tap  bearings  into  the  case  housing  bore and into place on the shaft. (7)     Push the input shaft as far to the rear of the case housing  as  it  will  go.    Then  push  the   underdrive pinion gear toward the front of the case.  Install the split  retaining  ring  (20)in  place  in  the  half  round groove  that  should  now  be  exposed.    Check  for proper fit. (8) Install  the  input  seal  carrier  gasket  (90)  and  the input  seal  carrier  (17)  along  with  seal(91)  on  the front   of   the   case   housing.      Coat   retaining   bolt threads  in  sealant  (Appendix  D,    Item  47),    install and torque bolts (92) to45 ft-lb (61.02 N.m) 6-102

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