Basics of Service DROP BOX DROP BOX FT 60, 70 & INTRODUCTION

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1 DROP BOX FT 60, 70 & INTRODUCTION Purpose of this drop box is to transmit the power from gear box to four wheel drive. It can be called Transfer box also and it takes drive from the drive pinion or bevel pinion which drives the crown pinion. Drop box and front axle is connected through propeller shaft. Since the front axle type used in FT 60, 70 & 80 is 4 wheel wheel Part time, it has one engaging lever for 2 wheel drive (2WD) and 4 wheel drive (4WD) selection HOUSING GROUP 1.2 DISASSEMBLY 1. Drain the oil completely from the transmission. Unscrew the bolts (12) and remove the group. EIFM Pub1.0/ April 07 1

2 2. Remove the fastening screws (7). Remove the cover (6). Note: the cover is attached with sealant. 3. Tap on the shaft end to release the transmission group bearings. Note: it s advisable to use a soft hammer to do not damage the shaft. 4. Remove the fastening screws (14). Disassemble the cover (13). Note: the cover is attached with sealant. 5. Remove the seal ring (15) from the cover (13) by mean of a pad and a hammer. Note: this is a destructive operation for the seal ring. 6. Remove transmission group. 7. Release the lock nut (24). 8. Remove the fastening screws (23). Danger: the spring (22) can be ejected with force against the operator. EIFM Pub1.0/ April 07 2

3 9. Collect the spring (22) and ball (21). 10.Remove the plug (19). Note: the plug is attached with sealant. 11.Remove the pin (20). 12.Extract the shaft (16). Danger: the ball (17) and spring (22) can be ejected with force against the operator. 13.Collect the ball (17) and spring (18). 14.Warning: collect with care the disassembled parts; they are necessary in the assembly operation. Note: remember the position of the springs (18) and (22). Check the disassembled parts wear condition. 15.Collect the fork (10). EIFM Pub1.0/ April 07 3

4 16.Remove the pin (2). 17.Remove the lever (10) and the shaft (9). Remove the spring (8). 18.Remove the seal ring (3). Note: this is a destructive operation for the seal ring. 1.3 ASSEMBLY 1. Clean with care the transmission housing. Check the wear condition of the housing. 2. Insert the seal ring (3) into the housing (4) with the special tool CA and a hammer. Lubricate the seal ring (3). 3. Respect indicated assembly position. Note: the springs (18) and (22) are not equal. 4. Insert the spring (18) and ball (17) into the housing (4). EIFM Pub1.0/ April 07 4

5 5. Insert the special tools CA into the housing (4). 6. Push with a punch the ball (17) on the spring (18) then insert the special tools CA on the ball (17). 7. Insert the fork shaft (16) in the housing (4) pushing forward the special tools CA Collect the special tools CA Assemble the spring (8) to the clutch shaft (9). 9. Assemble the lever (1) to the shaft (9). Note: align the pin hole in the shaft (9) to the hole in the housing (1). EIFM Pub1.0/ April 07 5

6 10.Lock the shaft (9) in the right position with a punch. Assemble the pin (2). 11.Assemble the fork (10) to the clutch shaft (9) in the housing (4). 12.Insert the shaft (16) in the fork (10). Note: align the pin hole in the shaft (16) to the hole in the fork (10). 13.Insert the fastening pin (20) with a punch and a hammer. 14.Apply sealant (B1) on the plug thread (19). Assemble the plug (19) and tighten it to the prescribed torque. EIFM Pub1.0/ April 07 6

7 15.Assemble transmission group. 16.Apply sealant (A2) on the screw thread (23). Adjust the screw (23) position to have 35 Nm of clutch torque value (M) on the lever axis. Assemble the nut (24) and tighten it to the prescribed torque. 17.Clean with care the covers (6) and (13). 18.Insert the seal ring (15) into the cover (13) with the special tool CA and a hammer. Lubricate the seal ring (15). 19.Apply sealant (A0) on the covers (6) and (13) on the housing/cover contact surface. 20.Assemble the covers (6) and (13) to the housing (4) with fastening screws (7) and (14). Tighten the fastening screws to the prescribed torque. EIFM Pub1.0/ April 07 7

8 21.Apply sealant (A0) on the housing contact surface. Assemble the housing to the transmission group with bolts (12). Tighten the bolts to the prescribed torque. Fill the transmission group with specified oil. Observe indicated 2WD/4WD clutch parameters. 2. TRANSMISSION GROUP 2.1 DISASSEMBLY 1. To disassemble the transmission group, remove the screws and disassemble the covers. EIFM Pub1.0/ April 07 8

9 2. Push the shaft (2) by mean of a pad and a hammer to extract the bearing (1) from the housing. 3. Remove the shaft/bearing group. 4. Remove the spacer (9) and the gear (10). 5. Remove the clutch sleeve (8). 6. Remove the bearing (1). 7. Remove the snap ring (3) to disassemble the clutch sleeve. Danger: the washer (4) and springs (7) can be ejected with force against the operator. EIFM Pub1.0/ April 07 9

10 8. Remove the washer (4). 9. Remove the springs (7). 10.Remove the sleeve (6) from the clutch sleeve (8). Collect the springs (7) 2.2 ASSEMBLY 1. Insert the bearing (11) into the transmission housing with the special tool CA and a hammer. 2. Insert springs (7) into the sleeve (6), to assemble the clutch sleeve group. 3. Assemble the sleeve (6) to the clutch sleeve (8). Note: check the springs (7) and key (5) position. 4. Assemble the washer (4). EIFM Pub1.0/ April 07 10

11 5. Assemble the snap ring (3). 6. Remove the clutch sleeve (8) to the fork (12). 7. Assemble the bearing (1) onto the shaft (2) with the special tool CA and a hammer. 8. Insert the spacer (9) and gear (10) in the housing. Assemble the shaft (2) with bearing (1) as shown. 9. Insert the bearing (1) and shaft (2) into the transmission housing with the special tool CA and a hammer. EIFM Pub1.0/ April 07 11

12 3. ADHESIVE/SEALANT APPLICATION POSITION: Apply on the contact surfaces Apply on bolts thread / on pins 4. SPECIFICATION Gear specification Dry weight Input rotation CLOCK WISE (C.W.) COUNTER CLOCK WISE (C.C.W.) Oil specification: USE RECOMMENDED OIL ENRICHED IN ADDITIVES. Grease specification Z=44/46 15 Kg API GL5 SAE 80W90 EP TECNOLUBE SEAL POLYMER 400/L (DIN = KHER1R ISO-I-XMR-XM2) Housing sealant (A0). SILASTIC 732 EIFM Pub1.0/ April 07 12

13 5. OVERALL DIMENSIONS: OIL DRAIN PLUG: To drain the oil remove the appropriate plug (1). Note: from the plug (1) you drain the oil from the whole vehicle transmission group. Warning: always remove the plug (1) to completely drain the old oil when replace the vehicle transmission oil (See vehicle repair manual). Clean the plug (1), assemble and tighten it to the prescribed torque (Sec.C.6). EIFM Pub1.0/ April 07 13

14 6. TIGHTENING TORQUES: EIFM Pub1.0/ April 07 14

15 7. TROUBLE SHOOTING Problem Cause Action 1. Oil leakage at the shaft 2. Oil leakage at housing cover 3. Oil leakage at the oil drain plug 4. Oil leakage between housing and upper part 5. Oil leak at upper part in motor compartment 6. Banging noise at spur-gear stage 7. Grinding noise 1. Radial shaft seal incorrectly mounted or damaged 2. Running surface on the shaft damaged 1. Housing cover is not sealed 2. Bolts not tightened to specified torque 1. Dirt between sealing ring and housing 2. An old sealing ring was used 3. Plug not tightened to specified torque 1. Sealing surface not sealed off 2. Bolts not tightened to specified torque 1. Too much oil in transmission 2. Motor seal defective 1. Toothing on gear damaged 1. Bearing preload or backlash have not been adjusted exactly 2. Damaged bearings 1. Replace and mount radial shaft seal correctly 2. Replace shaft or rework running surface if possible 1. Seal off housing cover with sealant 2. Tighten bolts to specified torque 1. Clean 2. Use new sealing ring 3. Tighten plug to specified torque 1. Coat surface with specified sealant 2. Tighten bolts to specified torque 1. Check the oil level and top up if necessary 2. Replace motor seal 1. Examine tooth flanks for impact damage and replace the damaged gear 1. Check the cover assembly and tighten the fastening bolts to specified torque 2. Replace the bearings EIFM Pub1.0/ April 07 15

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