Internal Transfer Case Repair; Transfer Case Installation - JLG sky trak mmv Service Manual

Transfer Case and Drive Shafts
6.3.10

Internal Transfer Case Repair

Detailed transfer case service instructions covering
repair, disassembly, reassembly, adjustment and
troubleshooting information are provided in the ZF Model
TB 92-432 Transfer Case Operating and Repair Manual
(ZF part number 32.70.4950.6002, JLG part number
8990423).
6.3.11

Transfer Case Installation

IMPORTANT: To help ensure optimum performance, the
drive shaft assemblies are specially balanced as a unit at
the factory. When servicing any flange yoke, slip yoke, or
drive shaft tube, order a complete assembly if compo-
nents are bent or damaged. Refer to the appropriate
parts manual for ordering information.
1. Secure the transfer case (1) to a suitable
transmission jack or lifting device. Raise the transfer
case into position under the vehicle, within the engine
mount (subframe) and vehicle chassis. Use four new,
®
Loctite 242 (blue) coated M16 x 2 x 35 mm
capscrews (2) and four M16 lockwashers (3) to fasten
the transfer case to the chassis. Torque to 145 lb/ft
(197 Nm).
2. Install the front and rear axle drive shafts (4) to the
transfer case (8) (according to the alignment marks
made during removal, unless installing new drive shafts).
Install the end of the drive shaft with the slip yoke to
the axle (5). Secure the bearing cross to the yoke
using four capscrews (6) and two straps (7). Torque
to 60 lb/ft (81 Nm).
Install the other end of the drive shaft to the transfer
case (8) yoke and secure the bearing cross to the
yoke using four capscrews (9) and two straps (7).
Torque to 60 lb/ft (81 Nm).
6.6
2
3
1
MM2391
5
3. Install the transmission to transfer case input drive
shaft (10) according to the reference marks made
during removal. Bolt the flange yokes to the transfer
box and to the transmission using eight [4-Front and
4-Rear] 1/2-20 x 2.0" NF Grade 8 capscrews (11),
sixteen [8-Front and 8-Rear] 1/2" lockwashers (12)
and eight [4-Front and 4-Rear] 1/2-20 NF nuts (13).
Torque to 105 ±10 lb/ft (142 ±14 Nm).
11
12
12
13
4. Install the remote engine oil filter assembly (14) to
the transfer case (15). Secure in place using two
M16 x 2 x 45 mm capscrews (16) and M16
lockwashers (17). Torque to 145 lb/ft (197 Nm).
15
5. Connect the negative (-) battery cable (18) at the
negative (-) terminal on the battery in the engine side
battery box.
4
7
9
6
7
11
10
16
17
14
Model MMV Rev. 12/04
8
MM22502
13
12
MT0370