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43
WARNING
Always use suitable tools to align holes. DO
NOT USE HANDS OR FINGERS.
Proceed as follows:
58. Remove the snap ring (5) and slide out adjust
shim (4), front bearing (3), spacer (2) and rear
bearing (1).
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L1
55
60. Place the gear on a suitable bush (1) to raise
the inner assembly. Ensure also the snap ring
is raised.
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S = L1 - L2 - 0.05 mm
where:
S = Adjust shim (2).
L1 and L2 = Readings on the gear
0.05 mm = Decrease necessary to compensate for bearing increased pre-load deriving from tightening of the transmission
output shaft locknut.
If necessary, round off the value (S) to the
previous 0.05 mm.
L2
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Example:
Reading L1 = 10.25 mm.
Reading L2 = 7.33 mm.
Adjust shim:
S = 10.25 - 7.33 - 0.05 = 2.87 mm.
Adjust shim to be assembled is 2.85 mm.
Note: Available adjust shims for the shuttle driven
gear are listed on page 3.
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WARNING
Always use suitable tools to align holes. DO
NOT USE HANDS OR FINGERS.
Proceed as follows:
59
S = L- (0 to 0.06 mm)
where:
S = Adjust shim
L = Travel reading
0 to 0.06 mm = Input shaft bearing end
play.
65. Dismantle tools (2 and 3), remove cover (4), assemble the shim as previously found, reinstall
cover (4) and tools (2 and 3). Repeat step 64
and check end play is to specification, 0 to 0.06
mm. Remove tools (2 and 3).
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67. Dismantle tools (3 and 4), remove disc (1), replace test shim (Sp) with adjust shim (S1), reinstall disc (1) and tools (3 and 4). Repeat step
66 to check end play is to specification, 0 to
0.06 mm. Remove tools (3 and 4) and screw in
the output shaft lubrication plug.
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47
62
Pattern for application of sealant during installation of speed and range control assembly, upper cover and front cover of clutches A and B.
Sealants to be used are listed on page 1, Section 00.
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WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles, gloves and footwear.
Loosen retaining screws and remove the synchroniser position sensor (1) from the Hi-Lo
valve.
2.
2130
3.
Remove the retaining ring (3). Using a screwdriver, retrieve piston (4).
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4
5.
5
6.
6
7.
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8.
8
9.
10. Reassemble and reinstall the Hi-Lo transmission valve observing the following:
Reassembly and reinstallation follow the disassembly and removal procedures in reverse,
from step 9 back to step 1.
Refer to figures on page 11 for correct orientation of the different parts.
Ensure the valve body is thoroughly clean
(especially inner compartments).
Check seals and replace if damaged.
Before reinstalling the Hi-Lo transmission
valve, thoroughly clean and degrease mating
surfaces and apply a 2 mm. bead of sealant following the pattern shown in the figure on page
47.
Tighten to correct torques as detailed on
page 4.
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WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles, gloves and footwear.
1
Remove the Hi-Lo transmission control assembly as
follows:
1.
2.
1
3.
2
4.
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5.
Detach all electrical connectors (1) from solenoid valves and sensors.
4
6.
5
7.
WARNING
Always use suitable tools to align holes. DO
NOT USE HANDS OR FINGERS.
8.
Reinstall the speed and range control rail assembly to the speed clutch/transmission housing observing the following:
Reinstallation follows the removal procedure
in reverse, from step 7 back to step 1.
Before reassembling the speed and range control rail assembly to the speed clutch/transmission housing, thoroughly clean and degrease
mating surfaces and apply a 2 mm. bead of
sealant following the pattern shown in the figure on page 47.
Tighten to correct torques as detailed on page
4.
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WARNING
Handle all components with the greatest care.
Do not insert hands or fingers between the parts.
Wear suitable protection clothing, including goggles, gloves and footwear.
23608
2.
23609
2
3.
23610
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4.
1
23611
4
5.
23612
5
6.
2
6
7.
1
7
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9.
Reassembly follows the disassembly procedure in reverse, from step 8 back to step 1.
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25877
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