2. Hold the box flange and unscrew the nut. Remove the lock washer and dismantle the flange. Use a puller if necessary.
3. Remove the driven gear bolts and pull it out of the gearbox housing.
Fig. 9.3 Driven gear mounting unit to the transfer case
4. Using a screwdriver, carefully remove the oil seal. Be careful not to damage the gear shaft and mounting surfaces.
5. Using a socket or suitable piece of pipe, install the new seal.
6. Lubricate the inner and outer sealing lips.
7. Insert the flange, lock washer and nut.
8. Install the driven gear assembly into the gearbox housing.
9. Tighten the flange nut to the torque specified in the specification.
10. Remove the driven gear assembly from the gearbox again.
11. Measure the driven gear bearing preload.
This measurement, which indicates the resistance to rotation of the driven gear bearing, is very important. Place a 22 mm socket on the flange nut and insert a torque wrench into it, rotate the flange with the wrench. Compare the force on the wrench with the data
specifications If the pre-tension force is less than the specified value, slightly tighten the flange nut. If the force is greater than the specified value, a new spacer must be installed between the bearing inside the housing. We recommend that the spacer be replaced only at a service station.
12. Install the driven gear assembly into place and tighten the mounting bolts to specification.
13. Attach the propeller shaft to the transfer case flange (see Section 4) and tighten the bolts to the force given in specifications.