Primary Gear Case - Taylor-Dunn B5-540-48XL Service And Replacement Parts Manual

Drive Axle-GT

PRIMARY GEAR CASE

WARNING
This section is one section of a complete service
manual. Before starting any procedure, read all
warnings and instructions that are located in the
Service Guidelines chapter.
1: Disconnect the batteries.
2: Raise the rear of the vehicle and support with jack
stands.
3: Place a drain pan under the gear case that is
capable of holding 4 liters (4 quarts) of oil and drain the oil from the front
gear case.
4: If required, remove the drive assembly from the vehicle. Refer to Remove
assembly procedure.
5: Remove the motor only if the entire drive is to be disassembled. Refer to
Motor procedure.
6: Remove the cover retaining bolts.
7: Remove the cover plate and let the remaining oil drain from the housing.
8: Remove the circlip from the idler gear.
9: Remove the input shaft/bearing assembly and idler gear/bearing assembly
from the gear case cover at the same time.
10: Remove the pinion nut from the output gear and remove the output gear
from the pinion shaft.
Note: If necessary, remove the seal from the input shaft bore at this time.
11: Mark the gear case position in relation to the 3rd member housing so that it
will be reassembled in the same position.
12: Remove the six retaining bolts holding the gear case to the 3rd member
housing.
13: Remove the gear case housing from the 3rd member housing.
14: Inspect all parts for signs of wear or damage.
15: Assemble the gear case in reverse order.
a. Apply gasket sealer (#94-430-05) to the front flange on the 3rd member and gear case cover.
b. Pack the motor seal with non-acetic based grease.
c . Torque the drain plug, gear case to 3rd member bolts, and pinion nut per torque listed in the Hardware
Torque table at the end of this section.
16: Fill the differential with oil. Refer to Check Oil Level for information on filling the drive with oil.
17: Lower the vehicle.
18: Reconnect the batteries.
19: Remove the blocks from behind the wheels.
20: Test drive the vehicle.
Page 42
B5-440-36 / B5-440-48 / B5-540-48XL / BF-030-48
Remove Idler & Input Assy.
Idler Gear Circlip
MB-440-06