24
Dealer Service
MAN1048 (4/16/2014)
DISASSEMBLE GEARBOX
(FIGURE 15)
1.
Remove vent plug (24) of gearbox and pour out
remaining gear oil.
2.
Support housing in vise with the input shaft in a
horizontal position.
3.
Remove the six cap screws (12) and washers (11)
from the input cap.
4.
Tap shaft with a hammer side to side to loosen the
cap from the housing. Once the cap is loose, pry
the cap out of the housing. Please note that the
cap, cap bearing, seal, shaft and gear will all come
out with the cap.
5.
With this cap, shaft and gear assembly removed
from the gearbox, remove retaining ring (22).
6.
Remove oil seal (6) from input cap.
7.
Support cap and press shaft through the gear.
Once the shaft and gear are separated from the
cap, remove retaining ring (7) from cap. Cap
bearing can now be removed.
8.
Remove input gaskets from the housing face and
cap.
9.
Support housing in a vise with the output shaft in a
horizontal position.
10.
With the hub/stump jumper/crossbar, castle nut,
cotter pin already removed, remove the four cap
screws (12), lock washers (11) and output cap
(16).
11.
Remove output gaskets (17) and (18).
12.
Push output shaft and pinion (20) down and
remove ball bearing (3), output bearing spacer
(10), retaining ring (22), shim (19) and remove
output shaft and pinion (20).
13.
Inspect gears for broken teeth and wear. Some
wear is normal and will show on loaded side.
Forged gear surfaces are rough when new. Check
that wear pattern is smooth.
14.
Inspect vertical and horizontal shafts for grooves,
nicks, or bumps in the areas where the seals seat.
Resurface any damage with emery cloth.
15.
Inspect housing and caps for cracks or other
damage.
REASSEMBLE GEARBOX
(FIGURE 15)
1.
Clean housing, paying specific attention to areas
where gaskets will be installed.
2.
Wash housing and all components thoroughly.
Select a clean area for gearbox assembly. Replace
all seals, bearings, and gaskets. All parts must be
clean and lightly oiled before reassembling.
3.
Slide ball bearing (3) on to output shaft and pinion
(20). Place against gear and secure with retaining
ring (22).
4.
Install shim (19) in output housing bore. Push
output shaft and pinion (20), ball bearing (3) and
retaining ring (22) into housing until ball bearing (3)
seats flat against the shim in housing socket.
5.
Insert output bearing spacer (10) and ball bearing
(3) over output shaft until it seats against inside
roller bearing (3).
6.
Secure output cap (16) with the new output seal
(13) installed to bottom of gearbox housing using
the four 10mm X 1.5 X 25 cap screws (12) and lock
washers (11).
NOTE:
Be sure output gaskets (17 and 18) are in
place. Use RTV silicone on gaskets for a leak free
seal. Apply grease to output seal (13) lip for easy
installation.
7.
Place ball bearing (21) at back of housing and
press in socket using a round tube of the correct
diameter and a hand press until fully seated.
8.
Press new ball bearing (3) into cap (2) socket by
using a round tube of the correct diameter and
hand press until fully seated.
9.
Install retaining ring (7) into input cap (2) to retain
the bearing (3).
10.
Install retaining ring (23) onto input shaft (4) in the
groove next to the spline. Press shaft (4) through
the bearing (3) that is installed in input cap (2) until
retaining ring is fully seated against bearing (3).
11.
Install input gear (23) onto input shaft (4) making
sure it is seated against bearing (3). Install
retaining ring (22) over the spline on input shaft (4)
and make sure it is fully seated against the gear
face.
12.
Install input shaft, cap, and gear assembly into
housing using one each input gasket (8) and one
each input gasket (9). Using a rubber hammer, tap
the end of the input shaft until the cap face is fully
seated against the gaskets and housing face.
13.
Check that the gear backlash is between 0.006”
and 0.016”. The backlash can be increased or
decreased by adding or removing gaskets between
the input cap and housing. Once the backlash is
correct add RTV silicone to the input cap face.
Install six each bolts (12) and six each washers
(11) to secure input cap assembly.
14.
Slide input seal (6) onto input shaft (4) and press
into housing flush with front using a tube of correct
diameter. Be careful not to damage seal lip.
15.
Check gearbox housing for leaks by plugging all
holes except one. Apply 4 psi compressed air and
immerse the gearbox in water to verify that there
are no leaks.
16.
Remove gearbox from water and dry off with
compressed air. With the gearbox placed in the
operating position add SAE 80W of 90W EP oil
