the retainer. Snap rings are a select fit. Use size A, B, C,
Rotate the shifter shaft while lowering the shift rail into the
or D to provide the tightest tit.
housing to prevent the link and rail from being disconnected.
(c) Install a low speed gear on the shaft with the
f. Install the drive chain in the chain housing, positioning
clutch end toward the gear end of the shaft.
it around the outer wall of the housing.
(d) Position the thrust washers on the shaft,
g. Install the chain housing on the range box (figure
17- 16), engaging the shift rail channel of the housing to the
alining the slot in the washer with the pin in the shaft.
shift rail. Position the chain on the input drive sprocket.
Slide or tap the washer into place.
h. Install the front output sprocket in the case, engaging
(e) Position the input bearing retainer on the
the drive chain to the sprocket. Rotate the clutch drive
shaft, and install a snap ring. Snap rings are a select fit.
gear to aid in positioning the chain on the drive sprocket.
Use size A, B, C, or D to provide the tightest fit.
i. Install the shift fork on the clutch assembly and shift
(f) Slide the spacer and thrust washer onto
sprocket. Push the clutch assembly fully into the drive
the shaft. Aline the spacer with the locator pin.
sprocket. Install the roll pin retaining shift fork to the
(g) Using heavy grease,
install the roller bearings
(15 required) in the end of the shaft.
j. Install the outer retainer ring on the front output
(h) Install a new "O" ring on the end of the shaft.
shaft bearing and install the bearing into the housing bore.
(5) Reassembling the lockout clutch assembly.
k. Install the front output shaft bearing retainer, gasket,
(a) Install a spring cup washer, spring, and
and retaining bolts.
sliding clutch gear on the front side gear.
l. Install the front output shaft seal, yoke, dust shield,
(b) Install the snap ring retaining sliding clutch
rubber seal, washer, and retaining nut. Tap the dust shield
to the front side gear.
back into place after installing the bolts in the flange.
(c) Using grease for retention, insert the
m Install the front output shaft rear bearing retainer
roller bearings (123 required) and spacers in the front side
gasket and retaining bolts. If the rear bearing was removed,
position the new bearing to the outside face oft he cover
and press it into the cover until it's flush with the opening.
(d) Install the thrust washer in the gear end of
the front side gear.
n. Install the differential carrier assembly on the input
shaft with the carrier bolt head toward the rear of the shaft,
(e) Slide the drive sprocket onto the clutch
splines and install the retaining ring.
o. Install the rear output housing assembly, gasket, and
retaining bolts (the load bearings in the pinion shaft).
(6) Reassembling the differential carrier assembly.
p. With the yoke nut about l/16-inch loose, push or
(a) Using grease for retention, install the
tap the end of the rear output shaft into the unit. This will
roller bearings (132 required, 33 on each pinion) into the
put the differential into close mesh for the next check.
Check the rear output shaft end play as follows:
(b) Install the pinion roller washer and gear,
(1) Install the dial indicator on the rear housing
and the roller washer and thrust washer on each leg of the
(2) Holding the rear yoke, rotate the front output
(c) Place the spider assembly into the front half
shaft to determine the highest point of axial movement in
of the carrier with the undercut surface of the spider thrust
the output shaft.
surface facing down or toward the gear teeth.
(3) Zero the dial indicator with the output shaft set
(d) Aline the marks on the carrier sections and
at this high point.
position the carrier halves together. Install retaining bolts
and tighten to 55 ft-lbs.
(4) Pull upon the yoke to determine the end play of
the shaft which is the gap between the bearing shoulders of
17-5. Reassembly of the Transfer.
the shaft and the housing.
q. Remove the dial indicator and install the shim pack
a. Place the range box on blocks with the front (input)
onto the shaft in the front of the bearing to get 0.010 inch
side down (figure 17-15).
end play. Hold the rear yoke and rotate the front output
shaft to check for binding of the rear output shaft.
b. Position a gasket on the range box.
r. Install the lockout clutch shift rail detent ball, spring,
c. Install the lockout clutch and drive sprocket assembly
and screw plug into the case.
on the input shaft.
s. Install the detent plate spring, gasket, and plug, if not
d. Install the input shaft, lockout clutch, and drive
installed during reassembly of the range box.
sprocket assembly into the range box, alining the tab on the
the shift levers
on the range box shifter
bearing retainer with the notch in the gasket.
u. Torque all
bolts, nuts, and plugs
(except the filler
e. Connect the lockout clutch shift rail to the connector
link and position the rail in the housing bore (figure 17-1 5).