Intermediate Gear Assembly

Overhaul

Intermediate Gear Assembly

Disassembly







1. Remove and discard 10 bolts securing bottom cover, remove cover.
2. Remove and discard 7 bolts securing differential lock selector side cover.







3. Remove side cover.







4. Release staking from intermediate shaft nut, remove and discard nut.
5. Remove bolt securing intermediate shaft retaining plate, remove plate.







6. Remove intermediate shaft and discard 2 'O' rings.
7. Remove intermediate gear assembly and collect bearings and selective or collapsible spacer. If a collapsible spacer is fitted, discard it.







8. Secure gear assembly in a soft jawed vice and using a suitable drift, remove and discard bearing tracks and circlips.

Reassembly

1. Clean gears, bearings, circlips and shaft.







2. Fit new circlips and using tool LRT-99-003 and LRT-41-006 fit bearing tracks to intermediate gear, ensuring that the bearing tracks are fully seated against the circlips.

T - Q Only: Proceed to Intermediate gear bearing preload T and Q Only

Intermediate gear bearing pre-load SE ONLY - METHOD 1







3. Using a micrometer, measure the width of each bearing inner track.
4. Record each reading as measurement 'A' and 'B', both measurements should fall within the range of 21.95 to 22.00 mm (0.864 to 0.866 in).
5. Fit inner bearing track 'A' onto tool LRT-41-017 and position intermediate gear cluster onto bearing 'A'.
6. Fit inner bearing track 'B' to intermediate gear, apply finger pressure to bearing inner track and rotate intermediate gear 5 to 10 turns to settle in bearing rollers.
7. Attach a DTI to base of tool LRT-41-017 and measure the step height between the top of tool post and the inner track of the bearing, take an average of the two readings and record this as measurement 'C'. Measurement 'C' should be in the range of 0.15 to 0.64mm (0.006 to 0.025 in).
8. Using the formula 103.554mm (4.0769 in) - 'A'-'B'-'C', calculate the length of bearing spacer required. From the result of the calculation round DOWN to the nearest length of spacer available to give a correct bearing pre-load of 0.05mm (0.002 in).
9. Remove intermediate gear assembly from tool LRT-41-017.
10. Lubricate and fit bearings and selected spacer to intermediate gear.

Proceed To Step 11

Intermediate gear bearing pre-load SE ONLY - METHOD 2
1. Lubricate and fit bearings and fit existing spacer.
2. Position tool LRT-41-004 through bearings and spacer.
3. Remove O-rings from main casing and intermediate shaft.
4. Position intermediate gear assembly and fit intermediate shaft and retaining plate.
5. Fit new intermediate shaft nut and tighten until intermediate gear end float is just eliminated.







6. Select neutral and fit tool LRT-41-005 into the input gear.
7. Check and record the torque required to turn the input gear.
8. Continue checking the torque while tightening the intermediate shaft nut to 88Nm (65 lbf. Ft.). If the increase in torque required to turn the gears exceeds 1.13 Nm (10 lbf. Ft.) during this operation, STOP, and fit a longer spacer.
9. With the intermediate shaft nut fully torqued to 88Nm (65 lbf. Ft.) the increase in torque required to turn the input gear should be 0.57 to 1.13 Nm (5 to 10 lbf. in.) above the torque recorded in step 7.
10. To increase the torque to turn, fit a shorter bearing spacer. To decrease, fit a longer spacer. Spacers are available in sizes from 58.35 to 59.30 mm (2.297 to 2.335 in.), in 0.05 mm (.002 in.) increments.

Proceed To Step 11

Intermediate gear bearing pre-load T and Q ONLY
1. Lubricate and fit bearings and new collapsible spacer.
2. Position tool LRT-41-004 through bearings and spacer.
3. Lubricate and fit 'O' rings to main casing and intermediate shaft.
4. With assistance, position intermediate gear assembly and fit intermediate shaft, while expelling LRT-41-004.
5. Rotate shaft until retaining plate can be located on flat on shaft.
6. Apply Loctite 290 to threads of retaining plate bolt, tighten bolt to 25 Nm (18 lbf.ft).
7. Fit new intermediate shaft nut and tighten in small stages until intermediate gear end float is just eliminated.
8. Select neutral and fit tool LRT-41-005 into the input gear.
9. Check and record the torque required to turn the input gear
10. Tighten the intermediate shaft nut in small stages, checking the torque to turn the input gears until the input gear torque to turn figure recorded in step 9 has increased by 1.25 Nm (10 lbf.in).

CAUTION: Take great care not to overtighten nut, as this will cause excessive bearing pre-load. If torque to turn figure is inadvertently exceeded, a new collapsible spacer must be fitted.

Proceed To Step 17

11. Position tool LRT-41-004 through bearings and spacer
12. Lubricate and fit 'O' rings to main casing and intermediate shaft
13. With assistance, position intermediate gear assembly and fit intermediate shaft
14. Rotate shaft until retaining plate can be located on flat on shaft
15. Apply Loctite 290 to threads of retaining plate bolt, tighten bolt to 25 Nm (18 lbf.ft)
16. Fit new intermediate shaft nut and tighten to 88 Nm (65 lbf.ft)
17. Stake flange of nut into recess on intermediate shaft
18. Clean transfer box bottom and side covers
19. Apply RTV sealant to both covers
20. Position side cover and tighten bolts to 25 Nm (18 lbf.ft).
21. Position bottom cover and tighten bolts to 25 Nm (18 lbf.ft).