Shift Rail and Fork Assembly.

TM 5-4210-224-14&P

6-24. TRANSFER CASE ASSEMBLY REPAIR. (Continued)

(3)

Install idler gear assembly (71) with dummy

shaft into case (5) through front output bore

(7) Install sliding clutch (59) onto fork (58) place

large end first.

over input shaft (8) in case. Position to receive

range rail and push rail through to neutral

(4) Install idler shaft (68) from large bore side and

position.

drive through using a soft hammer.

(8) Install new lock pins through holes at top of case

(5) Install washer (65) and new locknut (64). Check

and drive them into the forks. Tip case on PTO

for end play and free rotation. Torque nut to

opening when installing range rail lock pin.

150 ft-lbs (202 N ).

c. Front Output Shaft and Gear Assembly.

(6) Install idler shaft cover (66) and gasket (67).

Torque idler shaft cover bolts to 20 ft-lbs (27

(1)

Install two rows of needle bearings (46), (32

N ). Flat on cover must be located adjacent

each) separated by a spacer (47) in the front

to front output shaft rear cover (36).

low output gear (44) and retain with a sufficient

amount of grease (Appendix D, Item 15).

b. Shift Rail and Fork Assembly.

(2) Place front output shaft (35) in soft jawed vise,

(1) Press the two rail seals (76) into the case (5).

spline end down. Install front low gear (45)

Seals should be installed with metal lip

over shaft with clutch gear facing down and

outward.

install thrust washer pin (44), thrust washer (43)

and new snap ring (42) using snap ring pliers.

(2) Install interlock pins (63) through large bore or

Position the snap ring so that the opening is

PTO opening.

opposite the pin.

(3) Start front output drive shift rail (53) into case

(3)

Position front wheel hi-gear (38) and washer

(5) from back, slotted end first, with poppet

(39) in case. Install synchronizer (37) in the shift

notches up.

fork (57) then put fork and rail in the front wheel

drive (4-H) position with the clutch teeth in mesh

(4) Install shift fork (57) (long end inward) into rail,

with the teeth of the front wheel hi-gear.

push rail through to neutral position.

(4)

Line up washer (39) high gear (38) and

(5) Install input shaft bearing (72) and shaft (68)

synchronizer (37) with bearing bore. Insert

into case (5).

front output shaft (35) and low gear assembly

through the high gear assembly.

(6) Start range rail (52) into case (5) from front, with

poppet notches up.

6-58