Part 1

ASSEMBLY

Special Tools:














BEARINGS AND SEALS










1. Remove the input shaft bearing snap-ring from the front case half with suitable snap-ring pliers.
2. Remove the input shaft bearing from the front case half with Bearing Remover/Installer (3) and Universal Handle (2)(Figure 1).










3. Install the input shaft bearing into the front case half with Bearing Cup Installer (3) inverted on Universal Handle (2)(Figure 2).
4. Install the input shaft bearing snap-ring into the front case half with suitable snap-ring pliers.










5. Remove the front output shaft front bearing snap-ring from the front case half.
6. Using Bearing Remover/Installer (3) and Universal Handle (2)(Figure 3), remove the front output shaft front bearing.










7. Start front output shaft front bearing in case. Then seat bearing with Seal Installer (2)(Figure 4).
8. Install front output shaft bearing retaining ring.










9. Remove input gear pilot bearing by inserting a suitably sized drift (1)(Figure 5) into the splined end of the input gear (2) and driving the bearing out with the drift and a hammer.
10. Install new pilot bearing with Pilot Bearing Installer.










11. Remove the front output shaft rear bearing with the screw and jaws from Remover (2) and Cup (3)(Figure 6).










12. Install new bearing with Universal Handle (2) and Bearing Installer (3)(Figure 7).










13. The bearing bore is chamfered at the top. Install the bearing so it is flush (1) with the lower edge of this chamfer (2)(Figure 8).










14. Remove seal from oil pump with suitable pry tool.
15. Install new seal in oil pump with Seal Installer (2)(Figure 9).










16. Remove the rear output shaft bearing (2) snap-ring (3)(Figure 10) from the rear case half (1).










17. Remove the rear output shaft bearing from the rear case (1) using Seal Installer (2)(Figure 11).










18. Install the rear output shaft bearing into the rear case (1) using Seal Installer (3)(Figure 12) and Universal Handle (2).
19. Install the rear output shaft bearing snap-ring into the rear case half.

INPUT AND PLANETARY GEAR










1. Lubricate gears and thrust washers with recommended transmission fluid.
2. Install bottom thrust washer (2)(Figure 13) in low range gear planetary (1). Be sure washer tabs are properly aligned in gear notches.










3. Install input gear (1) in low range gear (2)(Figure 14). Be sure input gear is fully seated.










4. Install remaining thrust washer (2)(Figure 15) in low range gear and on top of input gear (1).










5. Install retainer (2)(Figure 16) on input gear (1).










6. Install snap-ring (2)(Figure 17).










7. Align and install low range/input gear assembly (2) in front case (1)(Figure 18). Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing.










8. Install snap-ring (2)(Figure 19) to hold input/low range gear (1) into front bearing.
9. Install a new input gear oil seal with Seal Installer and Universal Handle.