Dropbox Reconditioning

Service Information
Document Title: Function Group: Information Type: Date:

Dropbox removed, 434 Service Information 2/15/2016
reconditioning
Profile:
Manual Transmission, FLIL2 [GB]
Dropbox removed, reconditioning

Op nbr 434-029
Total procedure time (hr): 15.00
Tools:
9993812 Fixture
9993844 Regulator
9998534 Break out harness
11667001 Handle
11667010 Plug
11667060 Drift plate
11668022 Bracket
88890074 Multimeter
Guide pin, M12x120 mm.
2pcs. M12 lifting eyes
Sealant Loctite 518
Lock fluid Loctite 243
This operation also includes required tools and times for applicable parts of the following operations:
Rear output shaft, reconditioning

Differential lock control, reconditioning
Rear housing half, reconditioning
Lower main gear, reconditioning
Upper main gear, reconditioning
Shift fork, reconditioning
Differential housing, reconditioning
Oil pump, reconditioning
Front housing half, reconditioning
Dismantling
1. Remove the oil plug and drain the oil.

Figure 1
2. Install 11668022 Bracket on the dropbox. Lift the dropbox in the brackets with three lift slings.
Weight with bracket: 400 kg (882 lbs).
Weight without bracket: 375 kg (827 lbs)
Figure 2
3. Set up the dropbox in a stand. Bolt 11668022 Bracket to 9993812 Fixture which is secured on the stand.
Figure 3
4. Remove the bolts and the cover that hold the drive flange for the front output shaft. Lock the drive flange in a
suitable way.
Figure 4
5. Remove the drive flange. Use a suitable puller. Secure the puller in the drive flange with 2 bolts, UNF 1/2"x60 mm
(2.4 in). Use suitable counterhold.
Figure 5
6. Loosen and remove the oil pipe.

NOTE!
The upper pipe connection has a loose seal (sleeve and washer).
Figure 6
7. Remove the bolts (8 pcs.) for the dropbox's parting plane.
Figure 7
8. Rotate the dropbox 180.
9. Loosen the bolts and the cover that hold the drive flange for the rear output shaft. Lock the drive flange in a
suitable way.
Figure 8
10. Remove the drive flange. Use a suitable puller. Secure the puller in the drive flange with two bolts, UNF 1/2"x60 mm
(2.4 in). Use suitable counterhold.
Figure 9
11. Loosen and remove the bolts (9 pcs.) for the seal cover.
Figure 10
12. Install the lifting sling under the cover that holds the drive flange and fasten it to the shaft with three bolts.
Remove seal cover, bearing, and rear output shaft.
Weight: 30 kg (66 lbs)
Figure 11
13. Check the shaft with bearing and seal cover for damage, wear, and function. If needed, overhaul the shaft, see Rear
output shaft, reconditioning.
14. Remove the shims and the O-ring.
Figure 12
15. Loosen and remove the lock nut and the bolts (3 pcs.) for the cover over the differential lock control.
Figure 13
1. Bolt, M8x40 mm (3 pcs.)

2. Shaft
3. Lock nut
16. Remove the cover from the shaft for the longitudinal differential lock.
NOTE!
The cover is bolted on the shaft.
Figure 14
WARNING
Spring tension.
17. Secure the cylinder with three bolts M8x160 mm, provided with flat washer and nut. Remove the lock ring for the
piston.
NOTE!
The differential lock's spring has a preload of 120 mm (4.72 in).
Figure 15
18. Remove the Allen head bolts (2 pcs.) for the cylinder.
Figure 16
19. Release the spring preload by loosening the nuts on the attaching bolts. Loosen half a turn per nut at a time.
Figure 17
20. Remove the cylinder, the piston, and the spring.

Figure 18
21. Check the cylinder and piston for damage, wear, and function. Overhaul cylinder and piston if they are defective,
see Differential lock control, reconditioning.
22. Remove the remaining bolts (19 pcs.) for the dropbox's parting plane.
Figure 19
23. Remove the rear housing half. Use two lifting eyes M12 for lifting.
Figure 20
24. Check the rear housing half for damage and wear. If needed, overhaul the rear housing half, see Rear housing half,
reconditioning.
25. Remove the upper oil plate.
Figure 21
26. Remove the lower main gear.

Weight: approx. 30 kg (66 lbs)
Figure 22
27. Check the lower main gear for damage and wear. If needed, overhaul the main gear, see Lower main gear,
reconditioning.
The following applies to dropboxes for machines equipped with ATC:
28. Remove the speed (rpm) sensor.
Continued:
29. Remove the upper main gear and the shift fork for the differential lock.
Weight: approx. 30 kg (66 lbs)
Figure 23
30. Check the upper main gear and shift fork for damage and wear. If needed, overhaul the upper main gear and shift
fork, see Upper main gear, reconditioning and Shift fork, reconditioning.
31. Remove the lower oil plate.
Figure 24
33. Loosen and remove the bolts and the cover for the drive flange on the input shaft. Lock the drive flange with a bolt
or similar.
Figure 25
34. Remove the drive flange. Use a suitable puller. Secure the puller in the drive flange with two bolts provided with
washer and nut.
Figure 26
35. Loose and remove the bolts that secure the seal cover. Remove the seal cover.
Figure 27
36. Remove the shims.

Figure 28
37. Loosen and remove the bolts (16 pcs.) that hold the cover for the differential housing. Remove the cover. Use two
lifting eyes M12 for lifting.
NOTE!
Make sure that the seal surfaces are not damaged.
Figure 29
38. Remove the differential housing. Install a lift sling under the drive flange cover, and secure the cover to the shaft
with three bolts.
Figure 30
39. Check the differential housing for damage, wear, and function. If needed, overhaul the differential housing, see
Differential housing, reconditioning.
40. Loosen and remove the bolts, the seal cover, and the shims for the front output shaft.
The seal cover is loosened by screwing in existing bolts in the puller holes, located under the plastic plugs on the
seal cover.
Figure 31
41. Remove the protection for the ground-dependent hydraulic pump take-off.
Figure 32
42. Remove the drive sleeve for the ground-dependent hydraulic pump.
Figure 33
43. Loosen and remove the bolts for the oil pump.
Rotate the pump gear so that the markings on the pump gear and in the pump housing line up with each other.
NOTE!
The pump is locked with a ball in the gear's shaft.
Figure 34
Marking pump gear and pump housing
44. Remove the ground-dependent oil pump. The gear shaft may need to be rotated slightly so that the lock ball ends
up in the groove.
Figure 35
45. Check the oil pump for damage, wear, and function. Overhaul the oil pump if it is defective, see Oil pump,
reconditioning.
46. Remove the lock ring from the gear shaft.

Figure 36
47. Remove the lock ball from the gear shaft.
Figure 37
48. Tap carefully on the gear shaft so that it releases from the bearing.
Figure 38
49. Check the front housing half for damage and wear. If needed, overhaul the housing half, see Front housing half,
reconditioning.
WARNING
Risk of frostbite! Use protective gloves.
Oil pump, mounting
50. Cool the oil pump's gear shaft to a temperature not lower than 20 C (4 F).
51. Install the ground-dependent oil pump with four bolts. The oil pump is used as counterhold when driving in the
gear shaft.
Figure 39
52. Rotate the dropbox half a turn.
WARNING
Risk of frostbite! Use protective gloves.
53. Install the oil pump gear.

Tap down the gear against the bearing.
Figure 40
55. Remove the bolts that hold the oil pump, and remove the oil pump.
Figure 41
56. Install the lock ring for the gear shaft.
Figure 42
57. Fasten the lock ball on the gear shaft with some vaseline.
Figure 43
58. Turn the inner pump gear so that the ball groove ends up directly opposite the groove in the pump rotor carrier.
Apply sealant, Loctite 518 or equivalent, on the oil pump's contact face.
Figure 44
59. Place the gear shaft's marking so that it ends up directly opposite the marking in the oil pump.
Install the oil pump.
Figure 45
60. Install and tighten the bolts for the oil pump.
Tightening torque, see: Tightening torque
Figure 46
61. Install the drive sleeve for the ground-dependent pump.
Figure 47
62. Apply sealant, Loctite 518, on the oil pump.

Install the cover for the ground-dependent pump's take-off.
Differential case, installing
63. Install a lift sling under the drive flange cover, and fasten the cover to the shaft with three bolts.
Install the differential housing.
Figure 48
64. Drive out the bearing race for the input shaft from the differential housing cover. Use 11667001 Handle and
11667140 Drift plate.
Figure 49
65. Apply sealant, Loctite 518 or equivalent, on the differential housing cover's sealing face.
NOTE!
Apply sealant around the oil channel.
Figure 50
1. Oil channel
66. Install the cover for the differential housing. Use two M12 lifting eyes for lifting.
NOTE!
Line up the cover with the guide pins so that the oil channel ends up in the correct position.
Figure 51
67. Install and tighten the bolts crosswise.

Figure 52
WARNING
Risk of frostbite! Wear protective work gloves.
68. Cool the input shaft's outer bearing race to a temperature not lower than 20 C (4 F).
WARNING
69. Install the outer bearing race for the input shaft.
Tap down the bearing race against the bearing. Use a brass drift.
Rotate the shaft to ensure correct bearing position.
Figure 53
Axial clearance, input shaft: see Dropbox, specifications
Input shaft, shimming
70. Measure the distance between the differential housing cover and the bearing race (A). Note the value!
Figure 54
71. Measure the distance between the lug and the contact face on the seal cover (B). Note the value!
Figure 55
72. Calculate the distance between the bearing race and the seal cover's lug (C), that is:
C = A B where
C = distance between bearing race and seal cover's lug

A = distance between differential housing's cover and bearing race
B = distance between lug and contact face on seal cover
Total shim thickness (D) is determined by subtracting the axial clearance from C (= distance between bearing race
and seal cover's lug), that is D = C permitted axial clearance.
Axial clearance: see Dropbox, specifications
For information on thickness of available shims, see Parts Catalog.
Example:
Measured distance between differential housing's cover and bearing race = A = 7.35 mm (0.289 in).
Measured distance between lug and contact face on seal cover = B = 3.95 mm (0.155 in).
Then distance between bearing race and seal cover's lug (C) is:
C = 7.353.95 = 3.40 mm (0.2890.155 = 0.134 in)
The axial clearance should be between 0.060.10 mm (0.00240.0039 in), which gives that total shim thickness (D)
may vary between:
D = 3.40 0.08 = 3.32 mm (0.134 0.0031 = 0.1307 in) and
D = 3.40 0.12 = 3.28 mm (0.134 0.0047 = 0.1291335 in)
Select a shim with thickness 1.60 mm (0.063 in) and a shim with thickness 1.70 mm (0.067 in), which gives a total
shim thickness of 3.30 mm (0.130 in) and a clearance of 0.10 mm (0.004 in), which is within the permitted range.
73. Install the shims.
Figure 56
74. Drive out the seal rings from the seal cover. Use a suitable hammer and drift.
Figure 57
75. Drive in new seal rings in the seal cover.

Use 11667001 Handle and 11667120 Drift plate.
Figure 58
76. Install the seal cover and tighten the bolts crosswise.
NOTE!
Make sure that the oil channel ends up in the correct position.
Figure 59
77. Install a dial indicator with a magnetic stand.

Reset the dial indicator to zero and rotate the dropbox half a turn.
Check that the axial clearance is within the permitted range.
Axial clearance, input shaft: see Dropbox, specifications.
Figure 60
78. Loose and remove the bolts that secure the seal cover. Remove the seal cover.
79. Apply sealant, Loctite 518 or equivalent, on the seal cover.
Figure 61
80. Install the seal cover and tighten the bolts crosswise.
NOTE!
Figure 62
81. Install a dial indicator with a magnetic stand. Reset the dial indicator to zero and rotate the dropbox half a turn.
Check that the axial clearance is within the permitted range.
Axial clearance, input shaft: see Dropbox, specifications
Figure 63
Upper main gear, installing
82. Clean the threads in the holes in the front housing half where the lower oil plate is to be fastened with an M8
thread tap.
83. Install the lower oil plate with the two bolts closest to the upper main gear.
Apply lock fluid, Loctite 243 or equivalent, on the bolts.
NOTE!
Install one of the lower bolts, without lock fluid, as a guide for the oil plate.
Figure 64
84. Install the overflow valve in the front housing half.

NOTE!
Change the seal (no. 2 in Fig.) when installing the overflow valve.
Figure 65
1. Valve peg
2. Seal (shiny side facing valve peg)
3. Washer
4. Spring
5. Spring retainer
6. Ring
7. Lock ring
85. Install the lock ring for the overflow valve.
Figure 66
86. Apply lock fluid, Loctite 243 or equivalent, on the oil pipe's thread.
Fit the oil pipe.
NOTE!
The pipe shall protrude 60 1 mm (2.36 0.039 in). Make sure that the pipe's opening points at the bearing.
Figure 67
87. Lubricate the bottom pin on the shaft for the shift fork with vaseline.
Figure 68
88. Install the upper main gear and the shift fork for the differential lock.
Figure 69
89. Rotate the upper main gear and check that it is centred in the hole.
Check that the shift fork can be moved and pushed.
Figure 70
WARNING
Lower main gear and rear housing half, installing
90. Cool the bearing race for the front output shaft, lowest temperature allowed is-20 C (-4 F).
91. Install the bearing race for the front output shaft in the front housing half.
Figure 71
92. Tap down the bearing race approx. 3 mm (0.118 in) below the inner edge. Use a brass drift.
Figure 72
X = (distance bearing race inner edge) approx.3 mm (0.118 in)
93. Install the lower main gear.
Figure 73
The following applies to dropboxes for machines equipped with ATC:

94. Install the speed (rpm) sensor SE4309.
Figure 74
The following applies to all machines:
95. Remove the guide bolt for the lower oil plate.
Install the upper oil plate. Apply lock fluid on the bolts, Loctite 243 or equivalent.
Figure 75
96. Apply sealant, Loctite 518 or equivalent, on the front housing half.
Figure 76
97. Install the rear housing half.

NOTE!
Make sure that the upper oil plate enters in the rear housing half's bevel.
Figure 77
98. Install and tighten the bolts (19 pcs.).

Figure 78
Rear output shaft, installing
Install the output shaft without shims.
Figure 79
100. Measure the clearance between the bearing retainer and contact face on the housing. Measure in two places at the
same time. Note the value.
Install a dial indicator to check that the bearing retainer is not lifted during measuring
Figure 80
101. Calculate the required shim thickness.

This is done by adding required bearing clearance for the rear output shaft, with the measured value of the
clearance between the bearing retainer and contact face on the housing. Then select shims so that the thickness
matches the calculated value.
Bearing clearance, rear output shaft: see Dropbox, specifications
For thickness of available shims, see Parts Catalog.
NOTE!
Bearing clearance for the rear output shaft may not be less than the bearing clearance for the input shaft, see
Dropbox, specifications.
Example:
Measured value of clearance between bearing retainer and contact face on housing = 1.37 mm (0.0539 in)
Required bearing clearance for rear output shaft = 0.100.15 mm (0.00390.0059 in)
This gives that the shim thickness may vary between 1.37 + 0.10=1.47 mm (0.0539 + 0.0039 =0.0579 in) and 1.37 +
0.15 = 1.52 mm (0.0539 + 0.0059 = 0.0598 in).
Select a shim with thickness 1.50 mm (0.059 in), which gives a clearance of 0.13 mm (0.0051 in).
Remove the output shaft.
Figure 81
103. Turn the dropbox a further quarter of a turn.

Install a guide pin, M12x120 mm.
Figure 82
104. Install the shims, with a total thickness corresponding to the calculated shim thickness above.
Figure 83
1. Bearing carrier
2. Shims
3. Oring
105. Fit the Oring on the bearing retainer.

Smear vaseline on the O-ring.
Install a lift sling under the drive flange cover, and fasten the cover to the shaft with three bolts.
106. Fit the output shaft.

Check that the Oring does not move out of its position.
Figure 84
107. Turn back the dropbox a quarter turn.
108. Change seal rings in the seal cover.

Use 11667001 Handle and 11667120 Drift plate.
Figure 85
X = 56 mm (0.1970.236 in)

Figure 86
110. Install the seal cover and remove the guide pin.
Install and tighten the bolts.
Figure 87
112. Install and tighten the rest of the bolts for the dropbox's parting plane (8 pcs.).
Figure 88
Front output shaft, shimming
113. Tap down the bearing race so that stops against the bearing. Use a brass drift.
NOTE!
Rotate the shaft to ensure that correct bearing position is achieved.
Figure 89
114. Measure the distance between the bearing race and contact face for the seal cover (A). Note the value!
Figure 90
115. Measure the distance between the lug and the contact face on the seal cover (B). Note the value!
Figure 91
116. Determine shim thickness.

Calculate the clearance between the bearing race and the seal cover's lug (C).
C = A B, where
C = clearance between bearing race and seal cover's lug
A = distance between bearing race and contact face for seal cover
B = distance between lug and contact face on seal cover
Add the calculated clearance (C), to the bearing pre-load. Then combine shims so that it covers clearance and
bearing pre-load.
Bearing pre-load, front output shaft: see Dropbox, specifications
For information on thickness of available shims, see Parts Catalog.
Example:
A = distance between bearing race and contact face for seal cover = 11.30 mm (0.4449 in)
B = distance between lug and contact face on seal cover = 8.40 mm (0.3307 in)
The above gives that the clearance between the bearing race and the seal cover's lug becomes; C = 11.30 8.40 =
2.90 mm (0.4449 0.3307 = 0.1142 in)
Bearing pre-load should be between 0.08 and 0.12 mm (0.0031 0.0047 in), which gives that the shim thickness
may vary between 2.90 + 0.08 = 2.98 mm (0.1142 + 0.0031 = 0.1173 in) and 2.90 + 0.12 = 3.02 mm (0.1142 +
0.0047 = 0.1189 in).
Select two shims with thickness 1.50 mm (0.0590 in), which gives a total shim thickness of 3.00 mm (0.1181 in). Then
the bearing pre-load becomes 0.10 mm (0.0039 in), which is within the range for required bearing pre-load.
117. Install shims, matching total shim thickness calculated above, for the front output shaft.
Figure 92
118. Install the seal cover.

Measure the distance between the seal cover and the contact face. The distance should be the same as the bearing
pre-load.
Bearing pre-load, front output shaft: see Dropbox, specifications.
Figure 93
119. Remove the seal cover.
120. Change seal rings in the cover. Use 11667001 Handle and 11667118 Drift plate.
Figure 94
X = 56 mm (0.1970.236 in)
Figure 95
122. Install the seal cover and tighten the bolts.

Install the protective plugs for the puller holes.
NOTE!
Figure 96
123. Fit the oil pipe.
NOTE!
The upper pipe connection has a loose seal (sleeve and washer).
Figure 97
Control differential lock, installing
124. Lubricate the seal ring on the cylinder with vaseline.
125. Apply sealant Loctite 518 or equivalent on the underside of the cylinder's flange that seals against the transmission
housing.
126. Install the spring and the cylinder.

Install three bolts, M8x160 mm, with nut and flat washer.
Compress the spring, until the cylinder is about to enter in the housing, by tightening the nuts.
Tighten half a turn per nut at a time.
Figure 98
127. Fit a sleeve 32 with extension over the shaft for the shift fork.
Line up the shaft so that the cylinder can enter without damaging the seals.
Continue to tighten the nuts by half a turn per nut until the cylinder is all the way down.
Figure 99
128. Apply lock fluid, Loctite 243 or equivalent, on the bolts for the cylinder.
Install and tighten the bolts for the cylinder.
Figure 100
129. Smear vaseline on the seal ring and the O-ring on the piston.
Fit the piston.
Figure 101
130. Install the lock ring for the piston.
Figure 102
131. Pressurize the differential lock with max. 0.7 MPa (7 bar) (101.5 psi).
Check so that there are no air leaks.
132. Apply sealant, Loctite 518 or equivalent, on the cover.
Figure 103
133. Remove the three M8-bolts.

Fit the cover.
Tighten down the cover by turning the shaft counter-clockwise. Install one of the three M8-bolts as a guide.
Figure 104
134. Apply lock fluid, Loctite 243 or equivalent, on the bolts for the cover over the longitudinal differential lock. Install
and tighten the bolts for the cover.
Figure 105
WARNING
Risk of burns! Use protective work gloves.
Drive flange, installing
135. Heat the three drive flanges to max. 100 C (212 F).
136. Grease the seal rings on the seal cover for the rear output shaft.
WARNING
137. Install the drive flange on the rear output shaft.
138. Apply lock fluid, Loctite 243 or equivalent, on the drive flange's or cover's bevelled surface.
139. Apply lock fluid, Loctite 243 or equivalent, on the bolts for the cover.
Fit the cap and bolts.
Tighten the bolts. Lock the drive flange with a pry bar or similar.
141. Grease the seal rings on the seal cover for the input shaft.
WARNING
142. Install the drive flange on the input shaft.
143. Apply lock fluid, Loctite 243 or equivalent, on the drive flange's or cover's sealing face.
144. Fit the cap and bolts.

Use lock fluid on the bolts, Loctite 243 or equivalent.
Tighten the bolts. Lock the drive flange with a bolt or similar.
145. Grease the seal rings on the seal cover for the front output shaft.
WARNING
146. Install the drive flange on the front output shaft.
147. Apply lock fluid, Loctite 243 or equivalent, on the drive flange's and the cover's bevelled surface.
148. Apply lock fluid, Loctite 243 or equivalent, on the bolts.

Fit the cap and bolts.
Tighten the bolts. Install a bolt through the input drive flange as counterhold.
Figure 106
The differential lock is of the dog-clutch type with 100% locking. It is activated with spring force (spring pre-load approx.
120 mm (4.72 in)) and is deactivated with compressed air. Design of the differential dog-clutch halves is such that they
strive for full engagement at activation. The differential dog-clutch halves do not have to be pressed together to maintain
engagement. This means that the spring-loaded shift fork is to be adjusted so that it does not press against the differential
dog-clutch half when the differential lock is activated.
Differential lock, setting
149. Check that the differential lock is engaged (activated) by rotating the input shaft. If engaged, both output shafts
should rotate at the same speed.
150. Turn the shaft clockwise until it stops.

From stop position, turn the shaft counter-clockwise 45 turns.
Figure 107
151. Move the rear output shaft back and forth as much as the gear flank clearance allows.
At the same time, turn the shaft clockwise until the resistance on the rear output shaft increases (shift fork starts to
press on the differential dog-clutch half)
152. From the position where the shift fork begins to press on the differential dog-clutch half, the shaft is turned half a
turn counter-clockwise.
153. Connect equipment for pressurizing. Use 9993844 Regulator.

Pressurize the differential lock with max. 0.7 MPa (7 bar) (101.5 psi).
Figure 108
154. Check that the differential lock is deactivated, that is, disengages.
155. Remove the equipment for pressurizing.
156. Install the lock nut and lock the shaft in adjusted position. Use lock fluid on the lock nut, Loctite 243 or equivalent.
Sensor for differential lock, setting
157. Install 9998534 Break out harness on the sensor and connect 88890074 Multimeter to the cables marked 1 and 2.
Figure 109
158. Check that the differential lock is in mesh (activated).
159. Screw the sensor in until the circuit is closed.
160. Screw in the sensor another one full turn.
161. Apply lock fluid, Loctite 243 or equivalent, under the lock nut.
162. Secure the sensor with the lock nut.

NOTE!
Install new lock nut.
Figure 110
163. Check the function by pressurizing the differential lock with compressed air, max. 0.7 MPa (7 bar) (101.5 psi).
The sensor's circuit should be open when the differential lock is deactivated, that is, when it is not engaged.
Figure 111

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Service Information

Document Title: Function Group: Information Type: Date:

Dropbox removed, reconditioning

Total procedure time (hr): 15.00

Guide pin, M12x120 mm.

2pcs. M12 lifting eyes

Sealant Loctite 518

Lock fluid Loctite 243

Rear output shaft, reconditioning

1. Remove the oil plug and drain the oil.

6. Loosen and remove the oil pipe.

7. Remove the bolts (8 pcs.) for the dropbox's parting plane.

8. Rotate the dropbox 180.

14. Remove the shims and the O-ring.

1. Bolt, M8x40 mm (3 pcs.)

20. Remove the cylinder, the piston, and the spring.

25. Remove the upper oil plate.

26. Remove the lower main gear.

The following applies to dropboxes for machines equipped with ATC:

28. Remove the speed (rpm) sensor.

31. Remove the lower oil plate.

32. Rotate the dropbox 180.

36. Remove the shims.

46. Remove the lock ring from the gear shaft.

47. Remove the lock ball from the gear shaft.

Oil pump, mounting

52. Rotate the dropbox half a turn.

53. Install the oil pump gear.

54. Rotate the dropbox half a turn.

56. Install the lock ring for the gear shaft.

61. Install the drive sleeve for the ground-dependent pump.

62. Apply sealant, Loctite 518, on the oil pump.

Differential case, installing

67. Install and tighten the bolts crosswise.

Axial clearance, input shaft: see Dropbox, specifications

Input shaft, shimming

C = distance between bearing race and seal cover's lug

73. Install the shims.

75. Drive in new seal rings in the seal cover.

77. Install a dial indicator with a magnetic stand.

79. Apply sealant, Loctite 518 or equivalent, on the seal cover.

Upper main gear, installing

84. Install the overflow valve in the front housing half.

85. Install the lock ring for the overflow valve.

X = (distance bearing race inner edge) approx.3 mm (0.118 in)

93. Install the lower main gear.

The following applies to dropboxes for machines equipped with ATC:

The following applies to all machines:

97. Install the rear housing half.

98. Install and tighten the bolts (19 pcs.).

Rear output shaft, installing

101. Calculate the required shim thickness.

103. Turn the dropbox a further quarter of a turn.

105. Fit the Oring on the bearing retainer.

106. Fit the output shaft.

107. Turn back the dropbox a quarter turn.

108. Change seal rings in the seal cover.

109. Apply sealant, Loctite 518 or equivalent, on the seal cover.

111. Rotate the dropbox half a turn.

Front output shaft, shimming

116. Determine shim thickness.

118. Install the seal cover.

119. Remove the seal cover.

121. Apply sealant, Loctite 518 or equivalent, on the seal cover.