Lull 944E-42, Service Manual

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Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4
6.20 Model 644E-42/944E-42 Rev. 6/04
6.11 GENERAL INFORMATION
IMPORTANT: To help ensure optimum performance, the
drive shaft assemblies are specially balanced as a unit at
the factory. When servicing any flange yoke, slip yoke or
drive shaft tube, order a complete assembly if compo-
nents are bent or damaged. Refer to the appropriate parts
manual for ordering information.
Before performing any inspection, maintenance or
service operation, thoroughly clean the unit. The transfer
case and drive shafts should be checked and repaired
only by experienced service technicians who are aware
of all safety instructions and particular component
features.
Use suitable products to thoroughly clean all
disassembled mechanical parts to help prevent personal
injury to the worker and damage to the parts. Carefully
inspect the integrity of all moving parts (bearings, yokes,
tubes, gears, shafts, etc.) and fasteners (nuts, bolts,
washers, etc.) as they are subject to major stress and
wear. Always replace elastic locknuts and any damaged,
worn, cracked, seized, or otherwise improper parts that
could affect the safe and proper functioning of the
vehicle, transfer case and drive shafts.
6.12 TRANSFER CASE
6.12.1 Transfer Case Description
The ZF Model TB92-I4 transfer case is a single-speed,
mechanical unit designed for heavy-duty commercial use.
The transfer case is located beneath the frame of the
vehicle, mounted directly to the transmission.
6.12.2 Transfer Case Operation
Torque (twisting power) is transferred through a single
splined shaft directly from the transmission, into the
transfer case, and out to the drive axles via two drive
shafts, one for the front axle, one for the rear axle. The
transfer case is equipped with a set of four gears having
a 1:1 drive ratio.
Detailed transfer case service instructions covering repair,
disassembly, reassembly, adjustment and troubleshooting
information is provided in the ZF Model TB92-I4 Transfer
Case Operating and Repair Manual, JLG P/N 8990495
(ZF part number 5871.134.002). For example, transfer
case shaft bearing adjustment is accomplished during
disassembly/reassembly procedures not covered in this
manual; consult the ZF manual for information.
IMPORTANT: To help ensure optimum performance, the
drive shaft assemblies are specially balanced as a unit at
the factory. When servicing any flange yoke, slip yoke or
drive shaft tube, order a complete assembly if compo-
nents are bent or damaged. Refer to the appropriate
parts manual for ordering information.
The transfer case should be checked and repaired only
by experienced service technicians who are aware of all
safety instructions and particular component features.
6.12.3 Serial Number Plate
The ZF serial number plate (1) is riveted to the front of the
transfer case above the breather (2). Information
specified on the serial number plate includes Type (TB92-
I4), Serial Number, ZF reference number, Oil Specification
(oil type), and Ratios (final gear ratio, 1:1). Write this
information down in a convenient location to use in
transfer case correspondence.
6.12.4 Transfer Case Specifications
General transfer case specifications are found in Section
2.5, “Specifications.” Transfer case fluid information is
found in Section 2.6.7, “Transfer Case.”
WARNING:
DO NOT service the vehicle
without following all safety precautions as out-
lined in the “Safety Practices” section of this
manual. Failure to follow the safety practices
may result in death or serious injury.
MU1080
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