Troubleshooting; Transfer Case And Drive Shaft Troubleshooting - JLG sky trak mmv Service Manual

Transfer Case and Drive Shafts
6.5

TROUBLESHOOTING

This section provides an easy reference guide covering
the most common problems that occur during operation
of the transfer case.
Note: Contact the JLG Service Department at
1-717-485-5161 (Domestic) or 1-877-554-5438 (Interna-
tional), if internal transfer case repair is required during
the warranty period.
6.5.1

Transfer Case and Drive Shaft Troubleshooting

Problem
1. Excessive transfer case
noise.
2. Oil leaking from transfer case.
6.14
Detailed transfer case service instructions covering repair,
disassembly, reassembly, adjustment and troubleshooting
information is provided in the ZF Model TB 92-432 Trans-
fer Case Operating and Repair Manual (ZF part number
32.70.4950.6002, JLG part number 8990423).
The transfer case should be checked, serviced and re-
paired only by experienced service technicians who are
aware of all safety instructions and particular component
features.
Cause
1. Oil level too low.
2. Transfer case filled with
incorrect oil.
3. Excessive bearing "end play."
4. Worn or damage bearings.
5. Worn or broken gear teeth.
6. Contamination in the transfer
case.
7. Incorrect assembly of parts.
1. Breather blocked.
2. Plugs or fittings loose.
3. Incorrect oil level.
4. Gaps in sealant between
housing halves.
5. Worn, damaged or improperly
seated seals and/or worn or
damaged input/output shaft
sealing surfaces.
6. Damaged housing.
Remedy
1. Fill oil to correct level (refer to
Section 2.13.14, a. Transfer
Case Oil Level Check ).
2. Drain transfer case and fill to
correct level with recommended
oil (refer to Section 2.13.14, b.
Transfer Case Oil Change ).
3. Check bearing end play and
correct with shims as needed.
4. Replace bearings as needed.
5. Replace gears as needed.
6. Check for foreign particles.
7. Check assembly of transfer
case components.
1. Clean or replace breather.
2. Tighten plugs and fittings.
3. Fill oil to correct level (refer to
Section 2.13.14, a. Transfer
Case Oil Level Check ).
4. Clean housing mating surfaces,
apply new sealant (Loctite
and torque housing capscrews
to 34 lb/ft (46 Nm).
5. Replace seals and/or input/
output gear assemblies as
needed.
6. Replace housing.
Model MMV Rev. 12/04
®
518)