Drive Unit Rebuild - Disassembly
1.
Remove the drive unit from the truck.
CAUTION
DO NOT pry the sections apart - this may
damage the machined surfaces. If necessary,
use a rubber mallet to separate the sections.
2.
Remove the four nylon lock nuts (Figure 2.6
Item 14) and separate the gearbox from the
motor. Note the thickness of the shim
package.
3.
Remove the six screws (Figure 2.6 Item 26)
and separate the carrier from the housing.
Note the thickness of the old shim package,
then discard.
4.
If necessary, remove the bottom endbell
(including the pinion gear) from the motor.
There may be shim material around the motor
shaft in the pinion gear.
5.
Remove the O-ring (Figure 2.6 Item 12) and
discard.
6.
To disassemble pinion:
a.
Loosen the screw on the side of the clamp
nut (Figure 2.6 Item 2) and remove the
clamp nut using the pinion locknut wrench
(P/N 9660099) and 3/8” drive pinion
wrench (P/N 9660154-01).
b.
The spacer (Fig. 2.6 Item 3) and bearings
(Fig. 2.6 Item 5) are pressed onto the
pinion gear. Carefully press the pinion
gear out of the endbell. Press the lower
bearing off the pinion gear. Remove the
upper seal to remove the upper bearing
from the endbell.
c. To replace the lower seal, press both the
seal and the upper bearing cup out
together.
Drive Unit Rebuild - Assembly
Pinion Gear to Motor Endbell Assembly
NOTE
w
w
Before assembling the drive unit, all
components and machined surfaces must
be thoroughly cleaned of any dirt, grime,
gasket compound, etc. Machined surfaces
must be cleaned only by using a soft cloth
and mild, non-abrasive cleaning solvent.
1.
Refer to Figure 2.7 to assemble the pinion
gear to the motor endbell:
a.
Install the lower seal (lip down) and the
lower bearing cup.
b.
Pack the upper bearing with Mobilith SHC
220 synthetic grease (or equivalent) and
lubricate the lip of the lower seal. Press
the lower bearing all the way onto the
pinion using the pinion bearing press die
(P/N 9660100).
c. Cover the threads on the pinion to prevent
damaging the seal. Slide the pinion
through the endbell and remove the
thread covering.
d.
Use a hand press and the pinion bearing
press die (P/N 9660100) to press the
upper bearing and spacer onto the pinion
shaft. Rotate the endbell housing while
pressing. Stop pressing when slight drag
can be felt. Fill the upper bearing cavity
with Mobilith SHC 220 synthetic grease
(or equivalent), then install the upper seal.
E
lectric
C
ounterbalance
H
igh
O
utput
Drive
12/20/99
2.7
Figure 2.7- Pinion Gear to Endbell Assembly