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Figure 31
RING
GEAR
DIFF. BRG.
CAGE
REAR
OUTPUT
SPACERS
BRAKE
ADAPTER
Assemble Front Output
Shaft and Differential
Lockout Assembly
1. Rotate the transfer case in the repair stand so that
the front of the case is facing up. Figure 31.
2. Install the two internal front output cage mounting
capscrews and washers. Tighten the capscrews to
60-75 lb-ft (81-102 N•m).
3. Press the ball bearing on to the front output shaft.
4. Install the shaft collar on the end of the driven shaft
so that the dog teeth engage.
5. Install the front output shaft into the bearing cage and
through the shift collar.
6. Install the bearing retention snap ring into the bearing
cage.
7. Press a new oil seal into the bearing cage with the
correct size driver. Make sure that the seal is flat in
its bore and flush with the end face of the cage.
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 (877) 776-4600 / (407) 872-1901 • parts@eprogear.com
PLANET
GEAR
SUN
GEAR
PLANET
SHAFT
T
SET
SCREW
SPACER
8. Fit the shift fork through the cage opening and on to
the shift collar.
9. Install a new quad seal in the declutch piston. Make
sure that the seal is not twisted.
10. Coat the O.D. of the seal and the bore of the piston
in the output cage with a light film of oil.
11. Install the return spring and declutch shift piston into
the piston bore.
!
WARNING
To avoid serious personal injury, be careful when
using Loctite. Follow the manufacturer's
instructions for safe use to prevent irritation to
eyes and skin. Wash after skin contact. If the
Loctite gets in eyes, flush the eyes with water for
15 minutes. Have eyes checked by a doctor.
12. Apply one or two drops of Loctite 277 to the threads
in the shift fork. Assemble the fork on to the piston.
NOTE:
The piston return spring may have to be
compressed to assemble the fork on to the piston.
Section 5
Assembly
PLANETARY
SPIDER
FRONT
OUTPUT
Page 23
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