4.Remove four cap screws (9), flat washer (11), and remove shield (5) from gearbox.
5.Remove castle nut (14) and hardware from output shaft of gearbox.
6.Remove sheave (4) from gearbox.
7.Remove four bolts (9) that attach gearbox to gearbox stand and remove gearbox.
Gearbox Disassembly
Refer to Figure 18.
1.Remove top cover (22) from housing. Turn gearbox upside down and pour out remaining gear oil from gearbox.
2.Remove oil cap (20) (to be replaced).
3.Remove snap ring (10) and shim (13) from input shaft (3).
4.Support gearbox in hand press and push on input shaft (3) to remove bearing (7).
5.Remove gear (1) from inside housing.
6.Remove oil seal (19) from front of housing (to be replaced).
7.Remove snap ring (10) and shim (13) from front of housing (2).
8.Remove input bearing (7) by using a punch and hammer from outside of housing.
9.Support housing in vise in a horizontal position.
10.The castle nut (15) and cotter pin (25) are already removed with the drive sheave. Remove snap ring (21), washer (8), and seal (18).
11.Remove cotter pin (9), castle nut (14), and washer (17) from output shaft (4).
12.Remove output shaft (4) by using a punch and hammer and tap on top to drive down.
13.Remove gear (5) and shim (16) from inside housing.
14.Remove bearing (26) by using a punch and hammer from the top, outside the housing.
15.Support housing upside down (top cover surface) and remove bearing (6) by using a punch and hammer from the bottom side of the housing.
16.Inspect gears for broken teeth and wear. Some wear is normal and will show on loaded side. Forged gear surfaces are rough when new. Check that wear pattern is smooth.
17.Inspect vertical and horizontal shafts for grooves, nicks, or bumps in the areas where the seals seat. Resurface any damage with emery cloth.
18.Inspect housing and caps for cracks or other damage.
Gearbox Reassembly
Refer to Figure 18.
NOTE: Repair to this gearbox is limited to replacing bearings, seals, and gaskets. Replacing gears, shafts, and a housing is not cost effective. Purchasing a com- plete gearbox is more economical.
1.Clean housing, paying specific attention to areas where gaskets will be installed.
2.Wash housing and all components thoroughly. Select a clean area for gearbox assembly. Replace all seals, bearings, and gaskets. All parts must be clean and lightly oiled before reassembling.
3.Insert output bearings (6 & 26) in the housing, using a round tube of the correct diameter and a hand press.
4.Slide output shaft (4) through both bearings (6 &
26)until it rests against bearing (6).
5.Slide shim (16) over output shaft (4).
6.Press gear (5) onto output shaft (4) and secure with washer (17), castle nut (14), and cotter pin (9).
7.Apply grease to lower seal lips (18) and press seal over output shaft (4), using a tube of the correct diameter. Be sure not to damage the seal lip. Press in housing so that seal is recessed.
8.Insert protective washer (8) by hand. Install snap ring (21) and position it together with dual lip seal (18) by pressing it into position. Verify that snap ring is seated correctly.
9.Press bearing (7) into the housing, using a round tube of the correct diameter and a hand press. Secure with shim (13) and snap ring (10).
10.Secure snap ring (11) on input shaft (3) if not already secure.
11.Place gear (1) through top of housing and align gear (1) and gear (5) so that gear teeth are a match.
12.While holding gear (1) in place, slide input shaft (3) through gear (1) and bearing (7). Align splines on shaft (3) and gear (1).
13.Slide spacer (12) over input shaft (3) and press bearing onto input shaft (3), using a round tube of the correct diameter and a hand press.
14.Slide shim (13) over input shaft (3) and secure with snap ring (10).
15.Check input shaft end float by moving the input shaft (3) by hand. If end float is higher than 0.012”, insert shim between input shaft (3) and rear bearing (7). Repeat until end float is less than 0.012”. Check rotational torque by hand. The torque should be less than 2.2
26 Dealer Service | MAN0845 (1/12/2011) |
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