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Section 5
Assembly
2. Install the yoke and nut on the shaft finger tight.
3. Set a small steel ball in the hole on the end of the
output shaft.
4. Check the end play with a dial indicator mounted
against the ball on the shaft.
NOTE:
It is critical that the bearings be completely seated
in both directions.
a. Seat the lower bearings by using the weight of
the gear plus a rotational and shaking motion.
Proper seating of the lower bearings is indicated
when movement of the dial indicator ceases. At
this point, zero the dial indicator.
b. Using the same rotational and shaking motion,
apply upward lift sufficient to seat the upper
bearing. Proper seating of the upper bearing is
indicated when the dial indicator ceases to
register upward movement.
NOTE:
The movement indicated by the dial indicator is the
preliminary end play that exists with the initial shim
stack.
c. Subtract the appropriate shim quantity and
thickness to close the end plays to within the
specified limits.
Example:
0.058 in. (1.473 mm) Preliminary end play
-0.003 in. (0.076 mm) Nominal desired end play
=0.055 in. (1.39 mm) Shim stack to be removed
5. The end play must be between 0.001 - 0.005 inch
(0.025 - 0.127 mm). If it is not, different bearing
spacers must be used to achieve the correct end
play.
6. Six spacers of different widths are specified on the
T-2111 Bill of Material. Any two can be used to
achieve the correct end play. The six part numbers
and widths are:
2203-W-9851
0.478 in.
2203-X-9852
0.482 in.
2203-Y-9853
0.490 in.
2203-Z-9854
0.498 in.
2203-A-9855
0.506 in.
2203-B-9856
0.510 in.
Page 26
Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 (877) 776-4600 / (407) 872-1901 • parts@eprogear.com
7. Remove the yoke nut and yoke, then remove the
bearing cage/output shaft assembly from the transfer
case.
8. Press the shaft out of the assembly and identify the
two spacer part numbers.
9. Find the combined thickness of the two spacers
removed by using the above chart. If too much end
play exists, the combined spacer thickness must be
decreased by the amount of the excess end play.
If preload exists, the combined spacer thickness
must be increased by the amount of preload plus
0.001 inch (0.0254 mm).
10. Use the above chart to find two spacers with the
combined width to give the correct end play.
EXAMPLE:
Measured end play is 0.011 in. (0.2794 mm)
The two spacers removed are 2203-X-9852 and
2203-Y-9854.
The combined width of these spacers is:
2203-X-9852
2203-Y-9854
Since there is too much end play, the combined spacer
width must be decreased:
Measured end play:
Desired end play:
Required width decrease:
Old spacers combined width: 0.980 in.
Required decrease:
New spacer combined width: 0.972 in.
Reviewing the part number and width chart, replace the
2203-Y-9854 with 2203-Z-9853 to get the correct
combined spacer width:
2203-X-9852
2203-Z-9853
11. Repeat the assembly of the bearing cage/output
12.141 mm
shaft using the correct spacers.
12.243 mm
12.446 mm
12.649 mm
12.852 mm
12.954 mm
0.482 in.
12.243 mm
0.498 in.
12.649 mm
0.980 in.
24.892 mm
0.011 in.
0.2794 mm
0.003 in.
0.0762 mm
0.008 in.
0.2032 mm
24.8920 mm
0.008 in.
0.2032 mm
24.6888 mm
0.482 in.
12.243 mm
0.490 in.
12.446 mm
0.972 in.
24.689 mm
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