Output Shaft Seal - Installation

INSTALLATION

Special Tools:










1. Use the Seal Installer to install the output shaft seal into the front case half.
2. Install the Input Shaft assembly (1) into the Front Case Half (2).






NOTE: The output shaft sprocket is pressed onto the output shaft.

NOTE: If the Snap Ring (1) is temporarily installed too close to the top of the Output Shaft, it might not be possible to install it into the Bottom Groove on the Output Shaft after the Output Shaft Sprocket is pressed onto the Output Shaft.

3. Temporarily install the Snap Ring (1) approximately 3 mm (0.12 in.) above the Groove (3) on the Output Shaft.
4. Install the Output Shaft Sprocket, the Drive Chain and the Drive Sprocket as an assembly.






NOTE: When the Output Shaft Sprocket (2) is at the correct height, the Top Groove (1) on the Output Shaft will be visible.

5. Use the Installer and an arbor press to install the Output Shaft Sprocket (2) onto the Output Shaft. Press the sprocket until the Top Groove (1) on the Output Shaft is visible.





6. Press the Output Shaft upward with the Output Shaft Flange, then install the Snap Ring (1) into the Groove (3) on the Output Shaft.





7. Install the thrust washer (1) onto the Input Shaft (2).





8. Install the Clutch Assembly (1) onto the input Shaft (2).





9. Install the Snap Ring (1) onto the Input Shaft (2).





10. Install the wave spring (1) onto the input shaft.





11. Install the apply cam (2), and the ball bearings (1)





12. Install the clutch rotor (1) onto the input shaft.





13. Install the bearing (1) onto the input shaft.





14. Install the spacer (1)
.




15. Apply a bead of Loctite(R) 598 HB to the front case half sealing surface.
16. Install the rear cover (1). Tighten the case bolts to 31 Nm (23 ft. lbs).





17. Install the rear output flange (1)





18. Install a new outer rear output shaft seal (1)





19. Install the rear output flange washer (1)





20. Install the rear output flange nut.
21. Install Holder (1) onto the rear output flange (2). Tighten the rear output flange nut to 319 Nm (235 ft. lbs.).
22. Install the transfer case BW 44-40 Transfer Case - Installation.