Input Gear/Bearing

Input Gear/Bearing

Disassembly







1. Make alignment marks between cover plate/ bearing housing and main casing.
2. Remove and discard 5 bolts and stud nut securing cover/bearing housing to main casing. Remove cover and bearing housing.







3. Remove input gear assembly.







4. Remove and discard oil seal from main casing.







5. Drift out bearing track from main casing.







6. Drift out bearing track from housing and collect selective shim.







7. Position tool LRT-99-002 to vice.
8. Assemble tool LRT-41-003 to bearing, position input gear to hand press and remove bearing.
9. Repeat procedure for remaining bearing.

Reassembly
1. Clean input gear, cover/bearing housing and main casing.







2. Using tool LRT-99-002 and LRT-41-003 fit new bearings to input gear.
3. Using a suitable mandrel, fit bearing track to main casing.

Mainshaft Input Gear Bearing Pre-load Method 1

4. Fit a 3.15mm (0.12in) thick shim to bearing housing and using a suitable mandrel fit bearing track to housing.
5. Position input gear to main casing.
6. Fit bearing housing, ensuring reference marks are aligned, secure bearing housing with 2 bolts and tighten to 25 Nm (18 lbf.ft).
7. Position dial gauge with stylus contacting input gear, push input gear rearwards and zero gauge.
8. Push input gear forwards and note gauge reading.
9. Calculate thickness of shim required using the formula - A+B+C=D where:
- A= Thickness of installed shim
- B= Recorded end-float.
- C= Required pre-load - 0.05mm (0.002in).
- D= Thickness of shim required

10. If an alternative shim is required to establish correct pre-load, repeat the above procedure.
11. Remove 2 bolts, remove bearing housing and input gear.
12. Lubricate input gear and bearings with recommended oil.
13. Position input gear into main casing.
14. Apply liquid sealant to main casing.
15. Apply RTV to bearing housing cover.
16. Position bearing housing/cover, align reference marks and tighten bolts to 25 Nm (18 lbf.ft).
17. Using tool LRT-41-010 fit new input shaft oil seal.

Mainshaft Input Gear Bearing Pre-load Method 2
1. Secure bearing support plate in the vice. Drift out input bearing track, and remove shim.







2. Clean bearing support plate and shim.
3. Measure original shim and note its thickness.
4. Fit the original shim to the support plate.
5. Locate the bearing track in the support plate and press fully home.
6. Fit the bearing support plate onto the transfer box casing.
7. Place washers on six slave bolts (M10 x 30) to protect the sealing face.
8. Install slave bolts and torque to 40-50 Nm (29-37 lbf.in.).







9. Fit service tool LRT-41-005 to the input gear and engage the spline.

Torque-to-turn Method: Option 1

10. Tie a length of string to the split pin and fit it to the service tool as shown.
11. Attach a spring scale to the string and carefully tension the scale until a load-to-turn the input gear is obtained. Note load-to-turn value obtained.
12. A load-to-turn of 2.26 kg to 9 kg (5 lb. to 20 lb.) is required.

Torque-to-turn Method: Option 2

10. Select torque wrench able to measure between 0.56 and 2.26 Nm (5 and 20 lbf.in.).
11. Apply torque wrench to tool nut and note torque required to rotate the input gear
12. A torque-to-turn of 0.56 and 2.26 Nm (5 and 20 lbf.in.) is required.

All Transfer Gearboxes

13. If the reading obtained by the selected method is outside the above limits, the original shim must be changed
14. Remove the tools from the input gear.
15. Remove the six bolts and the bearing support plate.
16. Using a drift, remove the input gear bearing track from the support plate and discard the original shim.
17. Select the correct size shim to obtain a load-to-turn of 2.26 kg to 9 kg (5 lb. to 20 lb.) or torque-to-turn of 0.56 and 2.26 Nm (5 and 20 lbf.in.)
18. Fit new shim to support plate, locate bearing track and press home.
19. Fit bearing support plate and secure to transfer box casing with the six slave bolts.
20. Torque bolts to 40-50 Nm (29-37 lbf.ft.).
21. Repeat the torque-to-turn rolling resistance check using the same method selected previously.
22. Note the value obtained and ensure that it is within the specified parameters.