Part 1

ASSEMBLY

Special Tools:














BEARINGS AND SEALS










1. Remove the input shaft bearing snap-ring from the front case half with suitable snap-ring pliers.
2. Remove the input shaft bearing from the front case half with Bearing Installer (3) and Universal Handle (2)(Figure 1).










3. Install the input shaft bearing into the front case half with Bearing Cup Installer (3) inverted on Universal Handle (2)(Figure 2).
4. Install the input shaft bearing snap-ring into the front case half with suitable snap-ring pliers.










5. Remove the front output shaft front bearing snap-ring from the front case half.
6. Using Bearing Installer (3) and Universal Handle (2)(Figure 3), remove the front output shaft front bearing.










7. Start front output shaft front bearing in front case (1). Then seat bearing with Seal Installer (2)(Figure 4).
8. Install front output shaft bearing retaining ring.










9. Remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear (2) and driving the bearing out with the drift (1)(Figure 5) and a hammer.
10. Install new pilot bearing with Bearing Installer.










11. Remove the front output shaft rear bearing with the screw and jaws from Remover (2) and Cup (3)(Figure 6).










12. Install new bearing with Universal Handle (2) and Bearing Installer (3)(Figure 7).










13. The bearing bore is chamfered at the top. Install the bearing (1) so it is flush with the lower edge of this chamfer (2)(Figure 8).










14. Remove seal from oil pump with suitable pry tool.
15. Install new seal in oil pump (3) with Seal Installer (2)(Figure 9).










16. Remove the rear output shaft bearing snap-ring (3)(Figure 10) from the rear case half (1).










17. Remove the rear output shaft bearing from the rear case (1) using Seal Installer (2)(Figure 11).










18. Install the rear output shaft bearing (Figure 12) into the rear case (1) using Seal Installer (3) and Universal Handle (2).
19. Install the rear output shaft bearing snap-ring into the rear case half.

INPUT AND PLANETARY GEAR










1. Lubricate gears and thrust washers with recommended transmission fluid.
2. Install bottom thrust washer (2)(Figure 13) in low range gear planetary (1). Be sure washer tabs are properly aligned in gear notches.










3. Install input gear (1) in low range gear (2)(Figure 14). Be sure input gear is fully seated.










4. Install remaining thrust washer (2)(Figure 15) in low range gear and on top of input gear (1).










5. Install retainer (2)(Figure 16) on input gear (1).










6. Install snap-ring (2)(Figure 17).










7. Align and install low range/input gear assembly (2) in front case (1)(Figure 18). Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing.










8. Install snap-ring (2)(Figure 19) to hold input/low range gear (1) into front bearing.
9. Install a new input gear oil seal with Seal Installer and Universal Handle.

SHIFT FORKS AND MAINSHAFT










1. Lubricate mainshaft splines with recommended transmission fluid.
2. Coat the interior of the drive sprocket hub with ATF+4 and install the drive sprocket drive hub (2)(Figure 20) onto the mainshaft (1).










3. Install the mode hub (2)(Figure 21) onto the mainshaft (1).










4. Install the mode hub retaining ring (3)(Figure 22) onto the mainshaft (1).