Epicyclic Gear Set Replacement

REMOVAL
1. Remove viscous coupling assembly.





2. Remove 17 bolts securing halves of transfer box casing.
3. Carefully break RTV seal and remove front transfer gearbox casing from rear casing.
4. Position front casing, input shaft upwards. Position block of wood under epicyclic gear set.





5. Using a flat bladed screwdriver free of rough edges, ease input shaft oil seal from front casing.

CAUTION: Do not mark sealing surface of front casing.

6. Release circlip retaining epicyclic gear to front casing. Epicyclic gear set will fall onto block of wood.
7. Remove epicyclic gear set.

INSTALLATION
1. Clean RTV sealant from front and rear casing mating surfaces.

CAUTION: Do not use a metal scraper as this may damage sealing surfaces.

2. Clean bearing and input shaft mating faces.
3. Clean sealing area of front casing and running surface of input shaft. Ensure all traces of rubber are removed from sealing surfaces.

CAUTION: Do not use a metal scraper as this may damage sealing surfaces.

4. Install epicyclic gear set to front casing.
5. Install circlip retaining epicyclic gear set to front casing.
6. Lubricate sealing faces of seal with clean gearbox oil.





7. Using LRT-41-011 drift input shaft seal into front casing.
8. If removed, install 2 dowels to front casing.
9. Apply a continuous 2 mm bead of RTV sealant to rear casing mating face. Path to be around inside of bolt holes.
10. Install front casing to rear casing, ensure bolt holes are aligned before disturbing RTV sealant.
11. Install bolts securing front casing to rear casing and progressively tighten to 35 Nm (26 ft. lbs.).
12. Check freedom of rotation of input shaft and that rear output shaft rotates.
13. Install viscous coupling assembly.