Lull 944E-42 Service Manual - Manual (Page 198)

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4
6.22 Model 644E-42/944E-42 Rev. 6/04
6.12.9 Transfer Case Removal
Note: This operation can be performed with the engine/
transmission/transfer case still attached to the power
module.
1. Park the vehicle on a firm, level surface. Level the
vehicle, ground the attachment, place the travel
select lever in the (N), NEUTRAL DETENT position,
engage the parking brake switch and shut the
engine OFF.
2. Place an Accident Prevention Tag on both the
ignition key switch and steering wheel, stating that
the vehicle should not be operated.Section 1.5,
“Accident Prevention Tag Usage.” Unlock and open
the engine compartment cover. Allow the engine,
transmission and hydraulic fluid to cool.
3. If the vehicle has dual batteries, disconnect both
negative battery cables (1 and 2) from both
batteries.
To access the lower battery (3), loosen the knob (4)
far enough so that the lip (5) on the upper battery box
clears the knob. Lift up the upper battery box (6) and
swing it out, so that the box clears the hydraulic tank
support bracket, to gain access to the lower negative
battery cable (1). Disconnect the lower negative
battery cable.
4. Refer to Section 5.4.3, “Drive Shaft Removal,”
procedures for the removal of the drive shafts from
transfer case.
5. Prior to unbolting the transfer case, make certain
that a suitable lift/support device is in position to
carry the 350 + lbs (159 Kg) that the transfer case
weighs.
6. Remove the fourteen capscrews (12-rear (7) and 2
front (8)) securing the transfer case to the
transmission.
7. With the lifting/support device in position and ready
to accept the transfer case, Carefully pull the transfer
case away from the transmission (the case uses an
alignment pin (9) to correctly align the case to the
transmission). After the case has separated from the
pin, the case will need to be pulled approx. 2-3 more
inches from the transmission to fully disengage the
splined output shaft (10) protruding from the
transmission (11). Once the transfer case has
cleared the input shaft, lower the transfer case and
remove it from beneath the vehicle.
MU0650
1
2
3
4
5
6
MU1120
7
10
11
MU1130
8
9