Taylor-Dunn Bigfoot G-1500, Service And Parts Manual

Page: 46 / 118

Transmission
Page 46
Bigfoot G-1500
MB-440-10
DISASSEMBLE
Notes:
The brakes and axle shafts DO NOT need to be removed from the axle tube unless the axle or brakes
require servicing.
It is recommended to replace all oil seals.
A press will be required to reassemble.
A non-silicone based gasket sealer is required for reassembly. Us Loctite® 518 or equivalent.
1: Remove the transmission assembly from the vehicle.
2: Drain the oil from the transmission.
3: Remove both left and right axle tube/axle/brake
assemblies.
Note: Tag each assembly as left or right to make sure it is
reassembled correctly.
4: Remove the shifter detent screw, spring, and ball. A small
magnet can be used to extract the spring and ball from the
bore.
5: Place the assembly flat on a block with the input shaft
pointing down.
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.
WARNING
6: Remove all of the case bolts.
Note: There are 3 notches in each case half to be used to
split the case. DO NOT drive a screwdriver or pry bar
between the case halves or the sealing surface may
be damaged.
7: Using pry bars in the 3 notches, pry the two case halves
apart.
8: Remove the differential/ring gear assembly.
Note: Observe the orientation of the intermediate shaft
and input shaft gears, shims, and washers. Incorrect
reassembly will result in shifting problems.
9: Remove the thrust washer, drive and reverse gears from
the intermediate shaft.
10: Raise the input shaft slightly and remove the intermediate
shaft/gear assembly from the case. Do not forget the other
thrust washer.
11: Remove the retaining ring from the idler gear, slightly
raise the input shaft and remove the idler gear and thrust
washers.
Note: The idler shaft cannot be replaced. If it is damaged
then the case must be replaced.
12: Remove the input shaft.
13: Remove the shift actuator.
14: Remove all oil seals and discard.
15: Remove bearings as required.
Note: Bearings will be damaged when removed. Any
bearing that is removed must be replaced.
Showing Intermediate Shaft