TM-5-3805-254-14-P-2
TRUCK, DUMP, 20 TON, 6X4, ON-OFF HIGHWAY 71,000 GVW, IHC MODEL F-5070 (CCE)
TECHNICAL MANUAL; OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORT, GENERAL SUPPORT AND DEPT MAINTENANCE MANUAL (INCLUDING REPAIR PARTS INFORMATION AND SUPPLEMENTAL MAINTENANCE INSTRUCTIONS)
JUNE 1980
TM-5-3805-254-14-P-2 - Page 844 of 894
GEARS AND CASE
3. Coat thrust faces and splines of main shaft with
light grease. Enter pilot bearing end of main shaft
through rear bearing bore until main shaft has passed
through underdrive gear sleeve (B-13) approximately 1".
4. Place overdrive gear and sleeve assembly (B-7
thru B-10) in case with clutch teeth forward or away from
underdrive gear (B-12). Slide main shaft forward through
bore of sleeve (B-10).
NOTE
Check to make sure inner race of drive gear
pocket bearing (A-10) is in place in drive gear
counterbore.
5. Assemble direct and overdrive clutch collar (B-6)
to clutch gear (B-5). Extended hub of clutch collar
assembles toward front as does lock ring counterbore in
end of clutch gear (B-5). Position gear and collar in case
and assemble to main shaft spline.
6. Place a 1/2"
thick soft block (aluminum or brass)
between main drive gear (A-1) and direct and overdrive
clutch gear (B-5). Tap mainshaft forward until the lock
ring groove in splines at front of mainshaft extend beyond
face of clutch gear (B-5).
7. Assemble lo-lo gear thrust washer (B-21) on rear
of mainshaft with flat surface of washer toward lo-lo gear
(B-18) or clutch gear (B-17).
8. Position mainshaft rear bearing (B-22) onto
mainshaft with external snap ring away from case.
Use
pinch bar to lift mainshaft into position to align outer race
of bearing with rear case bore.
Tap rear bearing onto
mainshaft and into rear case bore.
If bearing taps into
position easily, then seat snap ring of bearing against
case and proceed to step 11.
9. If mainshaft rear bearing (B-22) does not tap into
position readily then remove
2" block between drive gear
(A-1) and clutch gear (B-5). Assemble lock ring (B-2) to
groove in mainshaft.
10. Use short length of 2Y " I.D. tubing with flange
washer and nut (B-27 and B-28) to pull mainshaft back
into its proper position and against rear mainshaft
bearing. Make sure ring is centered and seated inside of
clutch
gear
(B-5)
counterbore
during
mainshaft
positioning.
11. Remove puller tool or tubing from rear of
mainshaft and assemble rear bearing washer (B-23) and
speedometer gear or spacer washer (B-24) to mainshaft
and seat against rear bearing (B-22).
12. If mainshaft rear bearing cap oil seal (H-3) was
removed, then replace. Use gasket cement on O.D. of
seal and use seal installation tool to press into place. If
required, assemble new speedometer
gear bushing (H-2) in cap. Lubricate with engine oil and
assemble speedometer driven gear (H-21) and sleeve
(H-22) to cap. Check speedometer driven gear to make
sure it rotates freely and has .005-.008 end play.
13. Apply gasket cement to mainshaft rear bearing
cap gasket (H-4) and install on rear bearing cap. Align
the oil passage ports.
14. Apply gasket cement to other side of gasket and
assemble bearing cap and gasket to rear of case.
Dip
cap screws (H-5) in gasket cement and assemble to
case with copper washers (H-7).Torque cap screws 60
80 lbs. ft. then lockwire. Assemble dirt flinger on hub of
yoke or flange if removed.
15. Assemble end yoke or flange (B-25) to mainshaft
with pusher tool. Do not drive yoke or flange onto shaft
without provisions to block mainshaft overdrive gear (B-
7) against front of case with hardwood block. Be sure
lock ring (B-2) is in proper location.
CAUTION
If necessary to drive flanges or end yokes onto
mainshaft spline, take care not to damage flange
pilot surfaces or bearing diameters in yokes. Use
tubing and drive on hubs only.
16. Assemble flat washer (B-27) and nut (B-28) to
mainshaft. Lock unit in two gears and torque to 500 550
lbs. ft.
17. Shift clutch collars back into neutral and make
sure all shafts turn free.
18. Apply gasket cement to drive gear bearing cap
gasket (F-8) and install on drive gear bearing cap (F-7).
Align the oil passage ports.
19. Apply gasket cement to other side of gasket and
assemble drive gear bearing cap to front of case. Make
sure bearing cap is piloted on drive gear roller bearing
(A-9).
20. Dip cap screws (F-9) in gasket cement and
assemble to case with lock washers (F-10). Tighten and
torque drive gear bearing cap retaining cap screws, 60
80 lbs. ft.
21. Position outer roller bearing (A-7) with flange of
inner race facing drive gear splines, also outer race snap
ring toward splines on shaft of main drive gear (A-1). Use
tubing and drive on inner race of bearing. Seat bearing
tight against shoulder in bearing cap.
22. If used, assemble new lip seal (F-2) to front
bearing cap (F-l). Apply gasket cement to front bearing
cap cover gasket (F-3) and install on bearing cap cover
(F-l). Line up oil drain hole.
23. Apply gasket cement to other side of gasket and
assemble bearing cap cover to front of drive gear bearing
cap (F-7).
835
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