Secondary Gear Case; Disassemble; Assemble - Taylor-Dunn B5-540-48XL Service And Replacement Parts Manual

B5-440-36 / B5-440-48 / B5-540-48XL / BF-030-48

SECONDARY 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.

Disassemble

1: Remove the transaxle assembly from the vehicle.
Refer to Remove in this section.
2: 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 and secondary gear
case.
3: Place the axle assembly on an appropriate stand.
4: Remove the axle shafts and tubes as an
assembly by removing the six axle tube flange
bolts on each axle tube.
5: Remove the primary reduction gear case.
Refer to Primary Gear Case for information on
removing the gear case.
6: Remove the 12 side plate bolts, then remove the
side plate.
7: Remove the carrier bearing adjusting nut roll pin
and adjusting nut from the side
plate.
8: Turn the side plate over and
remove the carrier bearing race
from the side plate.
9: Remove the differential assembly.
10: Remove the carrier bearing
adjusting nut roll pin from the
carrier housing, then remove the
carrier adjusting nut.
11: Remove the carrier bearing race
from the 3rd member housing.
12: Remove the front bearing from the pinion gear
shaft.
Note: The pinion gear may have to be driven out
to perform this procedure.
13: Remove the pinion gear shims and spacer.
14: Remove the pinion gear from the carrier housing.
15: Remove the front and rear pinion bearing races.
16: Inspect all parts for signs of wear or damage.
17: Thoroughly clean all parts.
MB-440-06

Assemble

1: Temporarily install the pinion gear (hand tighten
only).
2: Install the carrier bearing race adjusting nuts into
the housing and cover.
3: Install the carrier bearing races into the housing
and cover.
4: Place the differential assembly into the housing.
5: Tighten the housing carrier bearing race adjusting
nut so that the ring gear is not in binding against
the pinion gear.
6: Remove the differential assembly.
Note: Do not allow the ring nut to rotate.
7: Remove the pinion gear and then reinstall the
differential assembly.
8: Install the cover onto the housing using 4-bolts in
a cross pattern and torque per torque listed in the
Hardware Torque table at the end of this section.
Roll Pin
9: Pre set the carrier bearing preload by tightening
the housing carrier bearing race adjusting nut
until it requires 2.1 - 4.7 Nm (1.5 to 3.3 foot
pounds) to rotate the differential assembly.
Note: Rotate the carrier assembly whenever
adjusting the ring nuts.
10: Mark the position of each carrier bearing
adjusting nut in relation to the drive housing and
cover and then remove the differential assembly,
do not allow the nuts to rotate.
11: Install the pinion gear. Re-shim if required. Refer
to Pinion Bearing Preload procedure.
Drive Axle-GT
Page 43