SkyTrak 3606 Service Manual - Manual (Page 130)

Section 6
6-6
6.3.5 Transfer Case Installation
IMPORTANT: To help ensure optimum performance, the
drive shaft assemblies are specially balanced as a unit at
the factory. When servicing any flange yoke, slip yoke, or
drive shaft tube, order a complete assembly if components
are bent or damaged. Refer to the Sky Trak International
Model 3606 Parts Manual for ordering information.
1. Secure the transfer case to a suitable transmission
jack or lifting device. Raise the transfer case into
position under the vehicle (see Fig. 6–2), within the
engine mount (subframe) and vehicle chassis. Use
new, case hardened 8.8-rated M16 x 2,0 x 75 mm
bolts and lock washers to fasten the transfer case to
the chassis. Torque to 156 lb/ft (210 Nm).
2. Install the front and rear axle drive shafts to the
transfer case (according to the alignment marks made
during removal, unless installing new drive shafts).
Bolt the flange yokes to the transfer case and axles
as required. Use new, Loctite
® 242 (blue) coated
grade 8.8 M12 x 1,75 x 35 mm hex-head capscrews,
flat washers and lockwashers. Torque to 83 lb/ft (113
Nm).
3. Install the transmission to transfer case input drive
shaft according to the reference marks made during
removal. Bolt the flange yokes to the transfer box and
to the transmission with new, Loctite
® 242 (blue)
coated grade 8.8 M12 x 1,75 x 35 mm hex-head
screws, flat washers and lockwashers. Torque to 83
lb/ft (113 Nm).
4. Move the hydraulic hoses into position and bolt the
bulkhead fitting bracket to the transfer case using two
of the M8 x 22 bolts securing the left side of the
center cover plate to the transfer case. Torque to
18 lb/ft (25 Nm).
5. Uncap and connect the hydraulic hoses to the
reservoir according to the marks made during
removal.
6. Install the engine mount rear cover plate.
6.4 DRIVE SHAFTS
6.4.1 Drive Shaft Inspection and Service
Whenever servicing the vehicle, conduct a visual inspec-
tion of the drive shafts and cross and bearing assemblies
(universal joints, or U-joints). A few moments spent doing
this can help prevent further problems and down time
later.
Inspect areas where the drive shaft flange yokes and slip
yokes mount to the drive shafts. Attempt to turn each
drive shaft in both directions. Look for excessive loose-
ness, missing parts, cracks or other damage. Worn or
damaged drive shafts (Fig. 6–4) and cross and bearing
assemblies may cause an excessive amount of vibration
or noise.
Figure 6–4. Drive shaft construction.
1. Individually inspect each cross, the bearing caps and
the needle bearings for signs of wear or for missing
parts.
Note: Replace the cross and bearing assembly as a
complete assembly if any parts are worn or missing. If all
parts of the cross and bearing assemblies are in good
condition, pack the bearing caps with a premium grade of
multi-purpose wheel-bearing grease. Reattach the bearing
cap to the cross, assuring that all needle bearings are
present. Then, reassemble the cross and bearing assem-
bly into the drive shaft yoke.
2. Replace the felt seal if worn or damaged.
3. Replace the entire drive shaft assembly if any flange
yoke, slip yoke, or drive shaft tube is severely dented
or damaged.
4. Cross assemblies should flex and be free from
excessive binding. A slight amount of drag or
resistance is desirable on a new cross and bearing
assembly. Excessive looseness causes unbalance.
6.4.2 Drive Shaft Maintenance
Information regarding checking lubricating the grease fit-
tings on the drive shafts is located in Section 2.5.3 Lubri-
cation Points (grease fittings).
Apply Loctite
242 (blue)
M12 bolt
Flat washer
Flange
yoke
Retaining ring
Bearing assembly
Cross assembly
Grease fitting
Slip yoke
Felt seal
Split retaining ring
Dust cap
Drive shaft
MS0500
Model 3606 • Origin 10/99