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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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