Model 279 Right Angle

Tranfer Case
Service Manual

For innovation using today's technology in demanding situations call:

Phone: (248) 477-9900 • Fax: (248) 477-7883
e-mail: e-mail: www.rcushman.com
R. Cushman & Associates • 32367 W. Eight Mile Road • Livonia, MI 48152
 279 Assembly Arrangement

279A

279 B&C 279 B & C

LUBE PUMP

279D LUBE PUMP

page 2
 279 Assembly Arrangement

DRAW WORKS SHIFT

LUBE DISTRIBUTION

OUTPUT PLUMBING 279B & 279C

LOWER SHAFT

279 & 279D

LOWER SHAFT

page 3
 279 Assembly Arrangement

DRAW WORKS
OUTPUT

279D PUMP

#8 JIC
OUTPUT TO
HEAT
EXCHANGER

page 4
279, 279B, 279C & 279D PLUMBING

page 5
279A PLUMBING ARRANGEMENT

page 6
 279 COMPONENTS

Item Part Number Quantity Part Name Where Used

1 279-10-1 1 Input housing 279, 279B, 279C, 279D

279-10-3 1 Input housing 279A
2 279-10-2 1 Housing 279, 279B, 279C, 279D
279-10-4 1 Housing 279A
3 705-10-4 1 Right angle housing 279, 279A, 279B, 279C, 279D
4 705-20-5B 1 Right angle cover 279, 279A, 279B, 279C, 279D
5 705-20-6 1 Bearing carrier 279, 279A, 279D
705-20-3 1 Bearing carrier 279B, 279C
6 705-20-7 1 Bearing carrier 279, 279A, 279D
279-20-2 1 Bearing carrier 279B
279-20-5 1 Bearing carrier 279C
7 705-20-8 2 Bearing retainer - input shaft 279, 279A, 279B, 279C, 279D
8 279-20-1 1 Intermediate pump cover 279, 279A, 279B, 279C
279-20-5 1 Intermediate pump cover 279D
9 705-20-10 1 Access cover 279, 279A, 279B, 279C, 279D
10 705-35-1 1 Shift collar 279, 279A, 279B, 279C, 279D
11 705-40-1 1 Input shaft 279, 279A, 279B, 279C, 279D
12 705-40-2 1 Input pinion shaft 279, 279A, 279D
279-40-4 1 Input pinion shaft 279B, 279C
13 705-40-3 1 Output shaft 279, 279A, 279B, 279D
279-40-5 1 Output shaft 279C
14 279-40-1 1 Intermediate pump shaft 279, 279A, 279B, 279C
279-40-6 1 Intermediate pump shaft 279D
15 279-40-2 1 Shift shaft 279, 279A, 279B, 279C, 279D
16 705-75-1 1 Spiral bevel hub - drive side 279, 279A, 279D
315-20-6 2 Cover - outputs 279B, 279C
17 705-75-2 1 Spiral bevel hub - driven side 279, 279A, 279D
279-75-1 1 Spiral bevel hub - driven side 279B, 279C
18 705-80-1A 3 Shim - .005" 279, 279A, 279B, 279C, 279D
705-80-1B 3 Shim - .007 279, 279A, 279B, 279C, 279D
705-80-1C 3 Shim - .020" 279, 279A, 279B, 279C, 279D
19 279-85-5 1 Lubrication guard 279, 279A, 279B, 279C, 279D
20 280-60-1 3 Gear/Bearing spacer 279, 279B, 279C, 279D
1 Gear/Bearing spacer 279A
21 279-20-4 1 Input cover 279, 279A, 279D
749-30-1 1 Spiral bevel pinion 279B, 279C
22 306-85-24 1 Shift piston 279, 279A, 279B, 279C, 279D
23 279-85-2 1 Air shift housing adapter 279, 279A, 279B, 279C, 279D
24 279-85-3 1 Air shift cylinder 279, 279A, 279B, 279C, 279D
25 279-85-4 1 Air inlet cylinder cap 279, 279A, 279B, 279C, 279D
26 623-30-1 1 Input gear 279, 279A, 279B, 279C, 279D
27 623A-30-2 1 Intermediate gear 279, 279A, 279B, 279C, 279D
28 623-30-3 1 Output gear 279, 279B, 279C, 279D
29 279-40-3 1 Output shaft 279, 279B, 279C, 279D
30 623-60-1 3 Gear/Bearing spacer 279, 279A, 279B, 279C, 279D
31 652-60-1 1 Spacer - drive side spiral bevel hub 279, 279A, 279D

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 279 COMPONENTS

32 652-65-1 1 Lock plate - output shaft 279, 279A, 279B, 279C, 279D
33 656-20-9 1 Intermediate bearing retainer 279, 279A, 279B, 279C, 279D
34 658-50-1 1 Shift fork 279, 279A, 279B, 279C, 279D
35 306-85-7 1 Shift return spring 279, 279A, 279B, 279C, 279D
40 316C 3 Disconnect assemblies - see pg 11 for parts 279, 279D
1 Disconnect assemblies - see pg 11 for parts 279A, 279B, 279C
41 279-85-7 1 Suction hose assembly 279D
42 745A 3 Bearing cone 279, 279B, 279C, 279D
1 Bearing cone 279A
43 257P36L36 1 Spiral bevel gear 279, 279A, 279D
35P42L21 1 Spiral bevel pinion 279B, 279C
44 257P36R36 1 Spiral bevel gear 279, 279A, 279D
35P21R42 1 Spiral bevel gear 279B, 279C
45 240B 1 Lubrication pump 279, 279A, 279B, 279C
D27BR2N020 1 Lubrication pump 279D
46 742 6 Bearing cup 279, 279B, 279C, 279D
4 Bearing cup 279A
47 749A 3 Bearing cone 279, 279A, 279B, 279C, 279D
48 HH221410 4 Bearing cup 279, 279A, 279B, 279C, 279D
49 HH221449 4 Bearing cone 279, 279A, 279B, 279C, 279D
50 20DU20 3 Bushing 279, 279D
1 Bushing 279A, 279B, 279C
51 AS324 1 O-ring 279, 279A, 279B, 279C, 279D
52 3720 1 Bearing cup 279B, 279C
53 3780 1 Bearing cone 279B, 279C
54 415725 1 Output seal 279, 279A, 279B, 279C, 279D
55 279-20-4 1 Input cover 279B, 279C
294-85-4 1 Pump drive adapter 279D
56 1/4x2.75 1 Pump drive dowel 279D
57 292-80-3A 9 Shim - .005" 279, 279B, 279C, 279D
6 Shim - .005" 279A
292-80-3B 9 Shim - .007" 279, 279B, 279C, 279D
6 Shim - .007" 279A
292-80-3C 9 Shim - .020" 279, 279B, 279C, 279D
6 Shim - .020" 279A
59 K23005 3 Shim - .005" 279, 279A, 279B, 279C, 279D
K23007 3 Shim - .007" 279, 279A, 279B, 279C, 279D
K23020 3 Shim - .020" 279, 279A, 279B, 279C, 279D
60 K23605 3 Shim - .005" 279, 279A, 279B, 279C, 279D
K23607 3 Shim - .007" 279, 279A, 279B, 279C, 279D
K23620 3 Shim - .020" 279, 279A, 279B, 279C, 279D
61 T50611 3 Shim - .005" 279, 279A, 279B, 279C, 279D
T50612 3 Shim - .007" 279, 279A, 279B, 279C, 279D
T50613 3 Shim - .020" 279, 279A, 279B, 279C, 279D
62 S10-100 1 Sump screen - lube system 279, 279A, 279B, 279C, 279D
63 3/8-16x1.00 29 Hex head cap screws - 279, 279B, 279C, 279D
15 Hex head cap screws 279A
64 3/8-16x1.50 6 Hex head cap screws 279D

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 279 COMPONENTS

65 3/8-16x1.50 12 Socket head cap screws 279, 279A, 279B, 279C

6 Socket head cap screws 279D
66 1/2-13x1.50 6 Hex head cap screws - 279, 279A, 279B, 279C, 279D
67 1/2-13x1.50 15 Hex head cap screws - drilled head 279, 279A, 279B, 279C, 279D
68 1/2-20x1.50 20 Hex head cap screws - drilled head 279, 279A, 279D
12 Hex head cap screws 279B, 279C
69 1/2-13x2.00 28 Hex head cap screws 279, 279A, 279B, 279C, 279D
70 5/8-11x1.50 6 Hex head cap screws 279, 279A, 279B, 279C, 279D
71 3/4-10x1.75 8 Hex head cap screws 279, 279A, 279B, 279C, 279D
72 1/4-20x.50 2 Socket head cap screws 279, 279A, 279B, 279C, 279D
74 1/2-13LN 34 Lock nut 279, 279B, 279C, 279D
28 Lock nut 279A
75 1.25-12LN 4 Lock nut 279, 279D
2 Lock nut 279A, 279B, 279C
76 3/8-16x.50 1 Socket head set screw - half dog 279, 279A, 279B, 279C, 279D
77 3/8-16x.25 1 Socket head set screw 279, 279A, 279B, 279C, 279D
78 1/2x1.25HPD 4 Hardened dowel 279, 279A, 279B, 279C, 279D
79 MBGF 1 Breather 279, 279A, 279B, 279C, 279D
80 208-85-3 4 Washer 279, 279D
2 Washer 279A, 279B, 279C
82 4CBU-S 9 Male ell 279, 279D
4 Male ell 279A
6 Male ell 279B, 279C
83 4FBU-S 2 Male connector 279, 279A, 279B, 279C, 279D
84 4-4CBU-S 2 Male ell 279, 279A, 279D
3 Male ell 279B, 279C
85 6C5BU-S 1 Male ell 279, 279A, 279B, 279C
8F50X-S 1 #8 o-ring/#8 straight - pump 279D
86 6-6FBU-S 2 Male connector 279, 279A, 279B, 279C
1 Male connector 279D
87 8C5BU-S 1 Male ell 279, 279B, 279C
2 Male ell 279A
12-10C50X-S 1 #10 o-ring/#12 JIC ell - pump 279D
88 4064021 1 Magnetic plug 279, 279A, 279B, 279C, 279D
89 4-6CBU-S 1 Male ell 279, 279A, 279B, 279C, 279D
90 1/2NPT 2 Plug 279, 279A, 279B, 279C, 279D
91 3/4NPT 3 Plug 279, 279A, 279B, 279C, 279D
92 1/8NPT 7 Plug 279, 279D
8 Plug 279A
6 Plug 279B, 279C
93 90AM2-2 1 Manifold 279, 279A, 279B, 279C, 279D
94 381174-2 1 Manifold 279, 279A, 279B, 279C, 279D
95 8FTX-S 1 3/8NPT/#8JIC - manifold 279D
98 1/16NPT 1 Plug - orficed fitting 279, 279D
3 Plug - orficed fitting 279A, 279B, 279C
99 1/4-28x.25 6 Set screw - orficed fittings 279, 279A, 279D
7 Set screw - orficed fittings 279B, 279C
100 8-12CBU-S 1 Male ell 279, 279A, 279B, 279C
12CTX-S 1 3/4NPT/#12JIC ell - suction line 279D

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 279 COMPONENTS

101 4R6BU-S 1 Union tee 279, 279A, 279B, 279C, 279D

104 6-6CBU-S 1 Male ell 279, 279A, 279B, 279C, 279D
106 NL8G 1 Lock washer 279B
107 1/4-20x6.00 3 Hex head cap screw - cylinder 279, 279A, 279B, 279C, 279D
108 711810 1 V block piston seal 279, 279A, 279B, 279C, 279D
109 UR112 1 Snap ring 279, 279A, 279B, 279C, 279D
110 AS031 1 O-ring 279, 279A, 279B, 279C, 279D
111 5/16-18x1.00 1 Flat head socket screw - piston 279, 279A, 279B, 279C, 279D
112 10-32x1.50 2 Socket head cap screws 279, 279A, 279B, 279C, 279D
113 4WBU-S 1 Bulkhead union 279, 279A, 279B, 279C, 279D
114 4SBU-S 1 Branch tee 279, 279A, 279B, 279C, 279D
115 3/16x.50 2 Hardened dowel 279, 279A, 279B, 279C
116 3/8-16x1.25 5 Socket head cap screw 279, 279A, 279B, 279C, 279D
117 5/16-18x.50 4 Socket head cap screw 279, 279A, 279B, 279C, 279D
118 1/2-13x2.50 10 Hex head cap screw 279, 279A, 279B, 279C, 279D
119 1/2-13x4.00 6 Stud NWT38406A 279, 279A, 279B, 279C, 279D
120 279-90-2 5 Male ell - special orfice 279, 279A, 279D
3 Male ell - special orfice 279B, 279C
121 279-90-3 1 Male ell - special orfice 279, 279D
3 Male ell - special orfice 279A, 279B, 279C
122 279-90-4 1 Branch tee - special orfice 279, 279A, 279B, 279C, 279D
123 279-90-5 1 Bulkhead union - special orfice 279, 279A, 279B, 279C, 279D
124 3/8x1/4PTR-S 1 Reducer 279A, 279B, 279C
125 294-60-2 2 Bearing spacer - disconnect bearing 279B, 279C
126 279-85-6A 1 Suction lube line 279, 279A, 279B, 279C
127 279-85-6B 1 Pump to manifold lube line 279, 279A, 279B, 279C
128 279-85-6C 1 Manifold to manifold lube line 279, 279A, 279B, 279C, 279D
129 279-85-6D 1 Input bearing lube line 279, 279A, 279B, 279C, 279D
130 279-85-6E 1 Front disconnect lube line 279, 279D
131 279-85-6F 1 Back lower disconnect lube line 279, 279B, 279C, 279D
132 279-85-6G 1 Back intermediate disconnect lube line 279, 279D
133 279-85-6H 1 Shift fork spray lube line 279, 279A, 279B, 279C, 279D
134 279-85-6I 1 Snout bearing lube line 279, 279A, 279B, 279C, 279D
135 279-85-6J 1 Right angle housing near bearing lube line 279, 279A, 279B, 279C, 279D
136 279-85-6K 1 Right angle housing far bearing lube line 279, 279A, 279B, 279C, 279D
137 279-85-6L 1 Bulkhead lube line 279, 279A, 279B, 279C, 279D

Installation Specific Components

1 279A 1 set Common components listed above 279A-1, 279A-2

2 37327 1 Input seal 279A-1, 279A-2
35083 2 Disconnect seal 279B-1, 279C-1
3 35083 1 Disconnect seal 279A-1, 279A-2
34889 1 Input seal 279B-1, 279C-1
4 8-4-861 1 Input yoke - 1880 BP 279A-1
8-1-27510 1 Input flange - 1880 279A-2
6-4-4551-1 1 Disconnect yoke - 1710 HR 279B-1, 279C-1
5 6.5-4-1901-1 1 Disconnect yoke - 1810 HR 279A-1, 279A-2
6.5-1-741 1 Input flange - 1810 279B-1, 279C-1

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 316C COMPONENTS
Item No. Part Number Quantity Part Name Where Used

1 316-10-3 1 Disconnect housing 316C

2 306-85-4 1 Air inlet cap 316C
3 316-35-1 1 Shift collar 316C
4 316-40-4 1 Disconnect output shaft 316C
5 316-40-2 1 Disconnect shift shaft NSS - see item 12 316C
6 306-50-2 1 Disconnect shift fork NSS - see item 12 316C
8 208-85-4 1 Oil dam 316C
9 306-85-5 1 Shift cylinder 316C
10 306-85-5 1 Shift piston 316C
11 LC105L9 1 Shift return spring 316C
12 316-85-1 1 Shift fork and shaft assembly 316C
13 6214 1 Ball bearing 316C
14 711080 1 V block seal 316C
15 35083 1 Output seal 316C
17 N5000-500 1 Snap ring - bearing retention 316C
18 RRT525 1 Snap ring - oil dam retention 316C
20 21-492 1 Shift signal switch 316C
21 7/16" 1 Steel ball - switch actuation 316C
22 1/8"NPT 2 Pipe plug 316C
23 238535 1 Breather 316C
24 AS026 1 O-ring 316C
25 AS027 1 O-ring 316C
26 1/4-20x1.75 3 Hex head cap screw - air inlet cap 316C
27 5/16-18x1.00 1 Flat head socket screw - piston retention 316C
28 1/4x1.250 1 Roll pin - disconnect housing positioning 316C

316C DISCONNECT

page 11
Initial Unit Disassembly

Prior to removing the unit from the equipment, drain the oil noting any accumulation of metal
on the magnetic drain plug (88). It is also helpful to retain a sample of the oil for further
observation.

After removal of the unit, support it securely in a vertical position with the transfer case down
being careful to properly support the right angle housing and the output snout. Disconnect and
remove the lubrication lines and the suction filter (62). Supporting the snout assembly, remove
the 8 screws (71) and separate this assembly from the right angle housing.

Remove the 10 screws (118) and 6 locknuts (74) holding the right angle housing to the transfer
case housing. Supporting it carefully, insert screws into the jackscrew holes supplied and
separate the right angle housing from the transfer case. The shift collar (10) can be removed
now.

Snout Disassembly

Remove the 3 screws (67) holding the lock plate (32). Remove the hub (17) with the right
hand spiral bevel gear attached. Remove the 10 screws (68) holding the gear to the hub and
separate the gear from the hub.

Remove the 6 socket head screws (65) holding the output cover (4) in place and remove the
cover. Press the shaft (13) through bearing cone (49) and remove the cone. Remove the bearing
cone (49) from the opposite end of the shaft. Press the bearing cups (48) from each end of the
snout housing (6).

Right Angle Housing Disassembly

Remove the 6 screws (70) from the cover/bearing carrier (5). While supporting the shaft (12),
remove the cover. The shift collar and fork assembly should remain with the transfer case
assembly. The pinion and spiral bevel gear assembly can now be removed through the hole
created by the removal of the cover (5).

Remove the 10 screws (68) holding the left hand spiral bevel gear (43) to gear hub (16) and
remove the gear. Press off gear hub (16) and bearing cone (49) from the gear end of the shaft
(12). Remove the gear hub spacer (31). Press off the bearing cone (49) from the opposite end
of the shaft.

Remove the 6 screws (67) holding bearing retainer (33) and remove the retainer. Press out
bearing cup (48).

page 12
Transfer Case Disassembly

Support the transfer case assembly securely with the right angle output housing side (2) down.
Remove the 5 screws (116) holding lubrication pump (45) to cover (8). Before removing the
pump, slide a wide putty knife under the pump as it is lifted off to prevent attaching and
operating components from falling off the pump.

Remove the 6 screws (65) holding the pump cover (8) to the housing and remove the cover. Keep
the shims (57) for use in the reassembly process. Remove the nut (75) and flat washer (80)
holding the end fitting to the input shaft (11) and remove the end fitting. For assembly 279,
perform the same removal process on the lower output end fitting.

Remove the 3 screws (107) from air cap (25) being careful to loosen them sequentially slowly
since the cap is under spring pressure. Remove cap (25) and spring (35). Remove piston screw
and washer (111)(124). Remove cylinder (24) with piston (22) and piston seal (51). If space is
available, the fork and shaft assembly (15)(34) can now be removed from the lower housing. The
shift collar (10) should have been removed with the right angle housing disassembly. Remove
shift adapter (23).

Remove the 6 screws from input bearing retainer (7) and remove the retainer keeping the shims
(57) for use in the reassembly process. For model 279, remove the 7 screws holding the output
disconnect assembly (40) and remove the assembly keeping the shims (57) for use in the
reassembly process.

Drive the dowels (78) at each end of the housing through both flanges. Remove the 28 screws
(69) and lock nuts (74) holding the flanges together. Using the jack screw holes provided,
separate the upper housing (1) from the lower housing (2). Remove the bearing cups (46) from
housing (1) – 279 3pc, 279A 2pc. Remove the gear and shaft assemblies from the lower housing
(2) – 279 3pc, 279A 2pc.

Turn the lower housing over and remove the one (279A) or two (279) disconnect assemblies (40)
by removing attaching screws (64). Remove 6 screws (67) from the input shaft bearing retainer
and remove the retainer. Remove the 3 bearing cups (279) or 2 cups (279A) from the housing (2).

Gear & Shaft Disassembly

Press input shaft (11) through gear (26), bearing (47) and spacer (30). Press the remaining
bearing (47) and spacer (30) from the shaft Press intermediate shaft (14) (the lower shaft on the
279A) through gear (27), bearing (47) and spacer (30). Press the remaining bearing (42) and
spacer (20) from the shaft. For model 279 only, press the lower shaft (29) through gear (28),
bearing (42) and spacer (20). Press the remaining bearing (42) and spacer (20) from the shaft.

page 13
Disconnect Disassembly

Remove 3 screws (26) from cylinder cap (2). Remove screw (27) from piston (10). Remove
cylinder (9) and piston (10). Remove switch (20) and actuation ball (21).
Remove snap ring (17) and oil dam (8) from the housing (1). Drive output shaft (4) along
with shift shaft and yoke assembly (12) from the housing (1). Remove seal (15), snap ring
(18) and bearing (13) from the housing (1)

Inspection

Thoroughly clean and inspect all components. Replace all seals and o-rings. Replace any
gear or bearing that shows signs of damage of fatigue, Make sure all housing flanges are
cleaned of old sealant and are free of any burrs, raised areas or oil residue.

Assembly

Start the assembly process with the disconnect assemblies (40). There could be 1, 2 or 3
based on the model. Install bearing (13) into housing (1). Install snap ring (18) into groove in
bearing bore. Place shift collar (3) onto output shaft (4). Insert shift fork/shaft assembly (12)
into collar (3) groove and install both shafts simultaneously into the housing and bearing.

Install o-ring (29) with air shift cylinder (9) into housing (1). Place V-block seal into the
groove in piston (10) so the lips point away from the housing. Apply a light film of grease on
the seal and install it into the cylinder. Install screw (27) through the piston into the shift rod
and tighten to 19lb-ft. Install o-ring (24) over cap (2) and install on cylinder. Place 3 screws
(26) through the cap and tighten into the housing evenly to prevent cocking of the cap or
cylinder. Tighten to 10lb-ft.

Place ball (21) into the threaded hole in the housing and install switch (20). Make sure the
switch operates properly when the shift shaft is moved. Install oil dam (8) and snap ring
(17). Make sure the dam does not interfere with the shift components. Install the seal (15).
The end fittings can be installed now with nut (41) and washer (42). They should be a slip fit
on the shaft. Apply RTV to the end fitting side of the washer before installing it. The nut
should be tightened to 300lb-ft.

Shaft Assembly

Note-If the bearings are heated for this assembly process, re-seat them after they have cooled
as they will move away from the shoulder as they cool. For the top shaft, press spacer (30)
and bearing cone (47) onto shaft (11) until the spacer bottoms on the shaft shoulder. Index
gear (26) splines with the shaft splines and install the gear. Press spacer (30) and bearing
cone (47) onto the shaft until the spacer bottoms on the shaft shoulder.

page 14
For the intermediate shaft (279) or lower shaft (279A) press spacer (20) and bearing cone
(47) onto shaft seating them against the shaft (14) shoulder. Index gear (27) on the splines
and slide into place. Press the remaining spacer (20) and bearing cone (470 onto shaft
seating them against the shaft shoulder. If bushing (50) has been removed from the end
(ends) of the shaft, press in a new bushing (bushings). For the 279 lower shaft repeat this
process.

Housing Assembly

Lay the output housing (2) face down and press bearing cups (46) into the housing just
below the surface so they will be pressed into position by the bearing covers. 2 in the
279A and 3 in the 279. Install the upper bearing retainer (21) with 6 screws (67), torque to
75lb-ft and safety wire the screw heads. Install the 1 or 2 disconnects with 7 screws (64)
each.

Flip the housing (2) over and support securely with the disconnect (s) down. Make sure
the bearing cups (46) previously installed are seated securely against the bearing covers.
Install input (11) and intermediate/output (14) shaft assemblies in place. Also install the
output shaft (29) in place in the 279.

Apply a continuous thin layer of Locktite 518 Red sealant to the mating flange of the
housing inside the bolt holes. Install input housing (1) onto housing (2). Insert and drive
dowels (78) thru holes at each end of the housings for alignment. Install 22 screws (69)
and locknuts (74) and torque to 75lb-ft Install 2 or 3 bearing cups in the bores of housing
(1) rotating the shafts to assure proper seating.

Input bearing adjustment – with bearing cup seated measure the depth from the housing
surface to the cup surface. Subtract the depth of the bearing cover pilot and subtract .003
for end play. The resultant dimension represents the amount of shims required. Install the
seal (52) in the cover. Apply a small bead of sealant to the cover close to the pilot and
install using 6 screws (64). Torque to 35lb-ft.

Intermediate shaft (279) or Output shaft (279 & 279A) – With bearing cup seated measure
the depth from the housing surface to the bearing cup surface. Subtract the depth of the
bearing cover pilot and subtract .003 for end play. The resultant dimension represents the
amount of shims required. Install the seal (52) if required, apply a thin bead of sealant
close to the cover pilot and install pump cover (8) using 6 socket head screws (65) and
torque to 35lb-ft.

Make sure pump cover (8) surface is clean, smooth and free from burrs. Apply a thin layer
of multi purpose grease to the pump flange surface and install the pump (45) taking care to
make sure no pump component has been displaced.

page 15
Snout Assembly

Install 2 bearing cups (48) into each end of the snout housing (6) and seat them solidly. Install 1
bearing cone (49) onto the output shaft (13) at the output end making sure it is seated against the
shoulder on the shaft.

Insert the shaft (13) into the output end of housing (6). Press 1 bearing cone on the input end of
shaft (13). Assemble the gear and hub assembly on the shaft (13) and retain with shims (61), lock
plate (32) and screws (67). Gradually adjust the amount of shims until an end play of .003/.005 is
reached. Torque the screws to 75lb-ft and lock wire the screws.

There are a few dimensions needed during the assembly process to properly set the bevel gears.
Measure the dimension from the gear seat to the mounting flange surface and record as dimension
“F”. Note the mounting dimension marked on the gear and record as dimension “E”. Install the
right hand bevel gear (44) onto hub (17) with 10 drilled head screws (68) torqued to 120lb-ft and
safety wire the heads. Install oil seal (53) into output cover (4). Apply a thin bead of Loctite 518
sealant to the mounting surface of the cover and install it with 6 socket head screws (65) torqued
to 35lb-ft.

Right Angle Housing Assembly

To assemble the pinion shaft assembly, place spacer (31) on shaft (12). Press hub (16) on shaft and
seat solidly against spacer (31). Press 2 bearing cones (49) on the shaft ends making sure they are
solidly seated against the shoulders. With the shaft (12) in a vertical position, temporarily
assemble a bearing cup (49) and bearing retainer (33) and measure the distance between the gear
seat and the bearing retainer mounting flange. Record this measurement as dimension “A”.

Install the left hand bevel gear (43) into hub (16) with 10 drilled head screws (68) torqued to
120lb-ft and safety wire the heads. Record dimension “C” marked on the housing and subtract
dimensions “A” & “B”. The result “D” is the number of shims required to be placed under
bearing retainer (33).

Place the appropriate number of shims under retainer (33) and attach it to housing (3) using 6
screws (67) tightened to 75lb-ft. Safety wire the heads. Install bearing cup (48) firmly in place in
the housing against the retainer pilot.

Install the pinion shaft (12) assembly into the housing (3) and seat into the bearing cup. Install a
bearing cup (48) in bearing carrier (5) and install on housing (3). Use enough shims under the
carrier for .003/.005 shaft end play. Install the carrier with sealant and 6 screws (70) tightened to
150lb-ft. Add the mounting distance on gear (44) “E” to dimension “F”. Subtract the dimension
“G” stamped on housing (3). The result “H” is the amount of shims required to mount the
assembled snout housing (6) to the fright angle housing (3). Install the shims (18) in the amount
“H” on the pilot of the snout housing (6), apply sealant, and mount the snout to the right angle
housint (3) using 8 screws (71) tightened to 260lb-ft.

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Disconnect Assembly

To assemble the disconnect assemblies 316C (40) used, install bearing (13) into housing (1) and
retain with snap ring (17). Install output shaft (4) into the bearing. Insert fork and shaft assembly
(12) into the groove in collar (3) and install into the disconnect housing on shaft (4). Install o-
ring (25) on shift cylinder (9) and install on housing (1). Apply a light grease film on v-block
seal (14) and install it into the groove in piston (10) so that the seal lip will point away from the
housing when installed. Carefully install the piston into the cylinder and attach the piston to the
shift shaft with screw (27) tightened to 19lb-ft. Install o-ring (24) over the pilot of cap (2) and
attach with 3 screws (26). Tighten sequentially to 10lb-ft. Install ball (21) and switch (20). Insert
oil dam (8) and snap ring (18) Make sure there is no interference with the oil dam and the switch
operates properly before mounting the disconnect assembly.

Final Assembly

Install shift fork (34) on shift shaft (15) aligning the set screw hole in the fork with the drill
point in the shaft. Install the dog point set screw (76) into the fork using Locktite 343 (blue)
thread locker. Then install cup point set screw (77) over (76) also with Locktite 343. Insert the
shift fork/shift rod assembly into the shift bores in housings (1) & (2). Install shift collar (10)
onto the fork and place on the splines of input shaft (11).

Install two dowels in right angle housing (3). Apply a thin continuous bead of Locktite 518
sealant around the flange of the housing (3). Align the housing on the dowels and seat. Install 6
nuts (74) and 10 screws (118) and tighten to 75lb-ft.

In adapter housing (23) install V-block seal (108) with seal lip toward the housing retained with
snap ring (109). Place the air shift adapter in the main housing counterbore. Install o ring seal
(51) in piston (22) and mount the piston on the end of the shift shaft (15) using the flat head
socket screw (111). Tighten to 17lb-in.

Place o-ring (110) over the adapter housing (23) pilot. Slide the cylinder (24) in place carefully
over the piston and seal to prevent cutting the seal. Install spring (35) into cap (25) and install
on the cylinder compressing the spring. Retain with 3 cap screws (107) tightened sequentially to
8lb-ft.

Install the cleaned suction filter, all plugs, lube lines and unit breather. Install lubrication
distribution guard (19) with 4 screws (117) tightened to 17lb-ft.

For innovation using today's technology in demanding situations call:

Phone: (248) 477-9900 • Fax: (248) 477-7883
e-mail: e-mail: www.rcushman.com
R. Cushman & Associates • 32367 W. Eight Mile Road • Livonia, MI 48152

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