Steps 31 - 70

31. Mount the rear output shaft in a soft-jaw vise with the input end up.
32. Remove the synchronizer assembly retaining ring.





33. Remove the synchronizer as an assembly.
34. Remove the synchronizer outer ring, middle ring, and inner ring.





35. Remove the shift detent spring bolt.
36. Remove the shift detent spring and the plunger.





37. Remove the shift shaft from the high/low range fork and the front case.





38. Remove the high/low range collar and the shift fork.





39. Remove the range collar from the shift fork.





40. Remove the front retaining ring for the drive sprocket from the drive sprocket sleeve.
41. Remove the drive sprocket sleeve from the rear output shaft.





42. If necessary, disassemble the synchronizer assembly.
^ Remove the inner ring (1)
^ Remove the middle ring (2)
^ Remove the outer ring (3)
^ Remove the synchronizer sleeve (4) from the hub (6)
^ Remove both insert springs (5 and 8) from the hub.
^ Remove the inserts (7).





43. Disassemble the range fork assembly, if necessary, for inspection.





44. Remove the front input shaft seal.





45. Remove the outer retaining ring for the input gear bearing.





46. Remove the high/low planetary carrier.





47. Remove the retaining ring for the input gear.





48. Remove the planetary carrier lock plate.





49. Remove the planetary carrier front thrust washer.





50. Remove the input gear,





51. Remove the planetary carrier rear thrust washers.





52. Inspect the needle bearing in the input gear for being faulty.
53. Remove the needle bearing and the cup plug from the input gear using a brass drift and a hammer, if faulty.





Important: For the super duty version of the NVG 263, it may be necessary to rotate the bearing in the front case in order to gain access to the retaining ring.
When removing the retaining ring for the input shaft bearing in the super heavy duty version of the NVG 263, the retaining ring must be fully expanded and then remove the input shaft bearing. DO NOT release the retaining ring until the input shaft bearing has been removed.

54. Remove the input gear bearing retaining ring.
55. Remove input gear bearing.





56. Remove the inner retaining ring for the front output shaft bearing.





57. Using a soft4ace hammer, remove the front output shaft, with the bearing, from the front case half.





58. Using a suitable punch, remove the front output shaft seal from the front case half.





59. Remove the outer retaining ring for the front output shaft bearing





60. Inspect the front output shaft bearing for being faulty.

61. Remove the bearing from the front output shaft. Do not use the bearing again after removal.





62. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.





63. Remove the front output shaft front bearing inner retaining ring.





64. Remove the front output shaft front bearing.





65. Inspect the front output shaft rear bearing for being faulty.
66. If the bearing is faulty, remove the bearing using the J 23907 (2) and the J 26941 (1).





67. Remove the shift detent lever retaining ring.





68. Remove the shift detent lever shaft.
69. Inspect the shift detent lever bearing and seal for being faulty.
70. If the seal or bearing is faulty, remove the bearing from the case.