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Input shaft assembly
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TM-5-4210-229-14P Truck Firefiighting 1000 GPM Multipurpose Model 2500L Manual
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Final assembly.
TM5-4210-229-14&P 6-18.  TRANSFER CASE REPAIR (Continued). (9) Coat  the  seal  surface  area  and  the   splines with Lubriplate (Appendix D, Item 34).  Install the yoke on the front of the input shaft. Lightly  coat  one  side  of  the  retaining  washer (93)  with  sealant  (Appendix  D,  Item  47)  and then  install  it  onto  the  shaft  with  the  coated side  facing  the  input  yoke.    Install  the  yoke retaining locknut (94) and torque it to 300 ft-lb (406.80 N.m). (10)    Temporarily   install   the   input   shaft   rear   cap (16)  without  shims  (95)  and  torque  bolts  (96) to   25   ft-lb   (33.90   N.m).      Measure   the   gap between the input shaft rear cap (16) and the case housing.  Select a shim stack that is 0.0 10 to 0.005 in.  larger than the gap dimension measured.    Remove  the  cap  (16)  and  then install  the  selected  shims  (95)  and  reinstall the  cap.    Coat  the  bolt  threads  with  sealant (Appendix D, Item 47), install and torque bolts (96) to 45 ft-lb (61.02 N.m). f. Shifter shafts assembly. NOTE There  are  three  shift  forks  used  in  this  transfer case.  Each shift fork is a different length. (1) Insert   the   shift   shaft   (14),   the   one   with   5 grooves,  into  the  shift  shaft  hole  next  to  the input shaft until the shaft is visible through the cover   opening.      Position   the   direct   drive clutch shift fork (6) (5-7/8 inches long) into the groove in the clutch on the input shaft with the long  hub  portion  of  the  shift  fork  facing  the front of the case.  Slide the shift shaft through the shift fork just enough to clear the underdrive shift fork (7) (7-5/8 inches long).  The  underdrive shift fork (7) should be installed  at  this  time  with  the  hub  portion  of the  shift  fork  facing  the  rear  of  the  case  and the forked end into the groove in the clutch on the  intermediate  shaft.    Slide  the  shift  shaft through this fork and into the hole on the back of the case. (2) Align     the     retaining     screw     hole     on     the underdrive   shift   fork   (7)   with   the   rear-most groove in the shift shaft.  Install the shift fork set  screw  (5)  into  the  fork.    Position  the  flat face of the eye end of the shift shaft paralleled to  a  line  through  the  input  and  rear  output shaft centerlines in order to put the flat side in a vertical plane on the installed case.  Torque the shift fork set screw to 25 ft-lb (33.90 N.m). (3) Slide  the  direct  drive  fork  (6)  and  clutch  to position the fork set screw hole over the next shift shaft groove and install set screw (5).  To insure maintenance of fork-to-clutch clearance,  hold  the  two  shift  forks  in  either clockwise   or   counterclockwise   direction   and then torque set screw.  Torque set screws (5) to 25 ft-lb (33.90 N.m)and lockwire (4). 6-103

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