Disassembly and Assembly

POWER TAKE OFF UNIT - DISASSEMBLY AND ASSEMBLY





Disassembly

Caution: Discard all seals after removing them.

Caution: Rotational torque of the power take off rear output shaft flange must be measured and recorded using an inch lbs. torque wrench for correct pinion bearing preload when reassembled.





1. Using the special tool to hold the power take off rear output shaft flange, remove the nut.

Caution: Mark the power take off rear output shaft flange relative to the pinion spline.





2. Using the special tool, remove the power take off rear output shaft flange.
3. Remove the power take off rear output shaft flange dust shield.
4. Remove the power take off rear output shaft flange oil seal.





5. Using the special tools, remove the power take off driven gear seal.

Caution: The power take off cover is located to the case using 2 hollow dowels. Remove the cover squarely from the dowels to avoid cracking the cover bosses.





6. Remove the 12 bolts and the power take off cover and gears.





7. Remove the gears.
1. Remove the drive gear. Remove the drive gear using a slight rotation to prevent damaging the power take off inner halfshaft seal.

Note: Remove the idle gear and the driven gear as an assembly.

2. Remove the idle gear.
3. Remove the driven gear.
8. Remove the power take off inner halfshaft seal
9. Clean the mating surfaces.

Assembly





1. Using the special tool, install the power takeoff inner halfshaft seal.

Caution: Take care not to roll the power take off inner halfshaft seal lip when installing the drive gear.





2. Install the gears.
1. Install the drive gear. Install the drive gear using a slight rotation to prevent damaging the power take off inner halfshaft seal.
2. Install the idle gear.
3. Install the driven gear.

Caution: The power take off cover must be installed within 15 minutes of applying the silicone sealant. If the time limit is exceeded, clean the sealing surfaces and reapply.





3. Apply sealant and install the power take off cover.

Note: Clean the inside of the driven gear of foreign material prior to installation of the power take off driven gear seal.





4. Using the special tools, install the power take off driven gear seal.





5. Using the special tool, install the power take off rear output shaft flange oil seal.





6. Using the special tool, install the power take off rear output shaft flange dust shield.

Caution: Install the power take off rear output shaft flange to engage the spline as previously marked.

7. Install the power take off rear output shaft flange.

Item 1: power take off Rear Output Shaft Flange Nut
Assembly Note

Caution: Do not over-tighten the pinion nut.

Caution: Refer to the rotational torque previously recorded with an in-lb torque wrench.

Caution: If the rotational torque is less than specification, tighten the drive pinion in small increments until it is within specification. Do not tighten the drive pinion nut more than 678 Nm (69.1 kgf-m, 500 ft. lbs.) or the collapsible spacer will be damaged. If the rotational torque is higher than specification, the collapsible spacer has been compressed too far and a now power take off must be installed.





8. Using the special tool, install the power take off rear output shaft flange nut.