32 Dealer Service
MAN0390 (Rev. 4/6/2007)
ASSEMBLE GEARBOX
Refer to Figure 20.
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. Install new bearing cup (16) in gearbox housing
and bearing cup (13) in cover if these parts were
previously removed.
4. Place bearing (16) and shim (5) on end of cross
shaft (4), and insert shaft into housing.
5. Install spacer (20), key (21), crown gear (7), shim
(18), and bearing (13) on opposite end of cross
shaft.
6. Place cover (12) over bearings (13) and secure
into position using eight cap screws (3). Torque cap
screws to 29 lbs-ft.
7. Place seal (11) over cross shaft and press into
housing. Use a round tube the same diameter of
the seal and a handpress. Repeat process on
opposite side of gearbox.
8. Install new bearing cup (16 & 13) into input housing
if these parts were previously removed.
9. Place bearing (16) over end of input shaft (14) and
insert shaft into front of input housing.
10. Place seal (17) over shaft and press into housing.
Use a round tube the same diameter of the seal
and a handpress.
11. Install bearing (13), shim (18), pinion gear (8), key
(10), shim (9) over opposite end of input shaft (14).
12. Secure parts together using lock nut (2). Tighten
lock nut (2) until shaft rolling torque is 3 to 9 lbs-
inch.
13. Insert input housing assembly into front of gearbox
housing and align teeth of the two gears. Secure
with cap screws (3). Torque cap screws to 29 lbs-ft.
14. Check gear backlash; it should be .006" to .017" at
outer tooth.
15. Check gearbox housing for leaks by plugging all
holes except one. Apply 4 psi compressed air and
immerse the gearbox in water to verify that there
are no leaks.
16. Remove gearbox from water and dry off with
compressed air. Add SAE 80W or 90W EP oil until
it runs out of the lower level hole in front cover.
Tighten all plugs.
REINSTALL GEARBOX
NOTE: Gearbox is heavy: do not attempt to move
without mechanical assistance.
1. Install flex coupler driveline between side
gearboxes and center gearbox.
2. Set gearbox on cutter and fasten with bolts and
nuts. Torque bolts to 300 lbs-ft.
SIDE DRIVE SERVICE
Figure 21. Side Drive Assembly
The drives between the center and side gearboxes
contain rubber shock-absorbing discs. To service or
remove the side drives or remove a gearbox, the flexi-
ble coupling must be disassembled.
Remove end yokes by removing nuts (9) and sliding
bolt (8) inward to clear yoke. Do not remove bolt unless
rubber discs (5) are to be serviced. Remove complete
center section by lifting straight up on center shaft (2).
The outer yoke can be slid off gearbox shaft. The inner
yoke is held by two set screws (11).
Reassemble shaft as shown in Figure 21. End yokes (3
& 4) do not bolt directly to center shaft (2). Use the spe-
cial formed washer (6) and bushings (7) between the
rubber discs (5) and under bolt head or nut near rubber
disc. Tighten the nuts (9) evenly until the formed wash-
ers (6) are slightly embedded into the rubber discs.
Rubber discs (5) will warp and twist if bolts are over-
tightened. Tighten set screw (11).
NOTE: Crossbar must be re-timed anytime a crossbar
or a side drive is disconnected.
6. Shaped washer
7. Bushing
8. Bolt
9. Lock nut
11. Set screw
2. Shaft
3. Inner yoke
4. Outer yoke
5. Rubber disc
