Section

501

TRANSMISSION AND TRANSFER CASE

REMOVAL AND INSTALLATION

DL Series Dynalift

907871/AP0998
PRINTED IN U.S.A.
Template Name: OML_2_col Rac 0-00000 Alt= to hide template information
Template Date: 1997_02_12 Alt+ to display template information
GENERAL TABLE OF CONTENTS
TRANSMISSION AND TRANSFER CASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TRANSFER CASE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TORQUE CONVERTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TORQUE CONVERTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TRANSFER CASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SPECIFICATIONS
Transmission Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Sunco Multi-ATI or equivalent
Transmission Fluid Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 U.S. quarts (11.4 L)
Transfer Case Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S.A.E. 40W Motor Oil
Transfer Case Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 U.S. quarts (2.8 L)

Transmission and Transfer Case U.S. Value Metric Value

Mounting Bracket Bolts and Lock Nuts . . . . . . . . . . . . . . . . . . . . . . . . .285 to 320 lb ft . . . . 385 to 435 Nm
Transmission Bell Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 to 37 lb ft . . . . . . 45 to 50 Nm
Torque Converter Flex Plate Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 to 37 lb ft . . . . . . 45 to 50 Nm
Transmission Fill Tube P-Clamp Bolt and Nut . . . . . . . . . . . . . . . . . . . .46 to 52 lb ft . . . . . . 63 to 72 Nm
Starter Relay Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 to 45 lb ft . . . . . . 54 to 61 Nm
Drive Shaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 to 46 lb ft . . . . . . 49 to 62 Nm
Transmission Cover Hinge Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 to 13.5 lb ft . . . 16.4 to 18.4 Nm

Front Grille and Radiator Grille

Mounting Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 to 10 lb ft . . . . . 12.2 to 13.7 Nm
Front Grille Brace Mounting Bolts and Nuts . . . . . . . . . . . . . . . . . . . . . 12 to 13.5 lb ft . . . 16.4 to 18.4 Nm
Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
TRANSMISSION AND TRANSFER CASE REMOVAL

STEP 1 STEP 3

G1230MP
Start the engine and raise the boom approximately 3
feet or 1 meter. Place a support stand under the
attachment mount. Carefully lower the boom onto the
stand.
Shut off the engine.
G1401MP
See Section 602, Hydraulic Pump Removal and
Installation section of this manufal for the correct
procedure to remove the hydraulic pump.
STEP 4

STEP 2

G1415MP

Remove the three serrated flange nuts and bolts to

remove the front grille brace.
G1393MP

See Section 201, Engine Removal and Installation STEP 5

section of this manual for the correct procedure to
remove the engine.

G1416MP

Remove the three serrated flange nuts and remove

the front grille.
PRINTED IN U.S.A. 501-1 907871/AP0998
Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 6 STEP 9

G1414MP G1417MP
Remove the two serrated flange nuts and hex head Open the transmission cover and remove the wire
bolts from the hydraulic tank fill tube mount. retaining pin from the rod end of the transmission
cover lift assist cylinder.
STEP 7
STEP 10
1

3
2

2
G1413MP

Remove the wires (1) from the horn. Remove the
cable tie (2) from the wire harness.
STEP 8
G1418MP
Remove the three nuts (1) and internal star lock
washers from the transmission cover hinges.
Remove the rod end (2) of the lift assist cylinder from
the ball stud.

Remove the transmission cover (3).

G1412MP

Remove the five serrated flange nuts from the

radiator grille and remove the grille.

PRINTED IN U.S.A. 501-2 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 11 STEP 14

2
1

3
4

G1419MP G1422MP

Remove the three front and three rear bolts from the
engine and transmission covers hinge mounting
bracket and remove the bracket from the machine.
STEP 12
3
Remove the bolt (1) and P-clamp (2) from the
transmission to transfer case mounting flange.
Remove the wire harness (3) and fuel hoses (4) from
the P-clamp.
STEP 15

G1420MP

Remove the wires from the transmission control G1423MP

solenoids (1), the reverse pressure switch (2) and the Remove the two bolts from the starter relay mount.
transmission temperature switch (3).

STEP 13

G1421MP

Remove the bolt from the ground wires on the left

side of the transmission.

PRINTED IN U.S.A. 501-3 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 16 STEP 18

G1424MP G1424MP

Remove the plug to drain the transmission fluid. Remove the four retaining bolts to remove the rear
drive shaft from the transmission.
NOTE: Because of the amount of fluid in the
transmission there is some head pressure at STEP 19
the plug and the fluid will propell from the
drain hole horizontally until most of the fluid
is drained. Use a catch pan or pan and
backdrop that will allow for the change in
drain pressure.

STEP 17

G1425MP

Remove the four retaining bolts and the front drive

shaft from the transmission.

STEP 20

G1442MP

Remove the transmission cooler hose from the lower

left rear corner of the transmission.

G1426MP

Remove the transmission fluid fill tube from the

transmission.

PRINTED IN U.S.A. 501-4 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 21 STEP 24
4

3
2
1
G1427 G1429MP
Remove the cable ties (1) and wire harness (2) from If equipped, move the cab heater hoses away from
the transmission fill tube. the rear of the transmission.
Remove the bolt (3) and P-clamp (4) from the
transmission to transfer case mounting flange. STEP 25

Remove the fill tube from the machine.

STEP 22

G1438MP

G1439MP
Install a strap around the wire harnesses and
hydraulic hoses and attach the strap to the boom to
hold the wires and hoses above the front left mount.

STEP 23

G1495MP

Use M12 x 25 Grade 10.9 bolts, to install lifting rings

or brackets on the front left and right mounting holes
(1) of the transmission.
NOTE: If using lifting rings with only one bolt each,
mount the rings in the lower holes (2).

G1428MP
Remove the transmission filter.
PRINTED IN U.S.A. 501-5 907871/AP0998
Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 26 STEP 28

G1440MP G1430MP

Install a load rotor between the lifting brackets or

rings and a hoist.

STEP 27

1 G1431MP

3
G1432MP

Remove the fuel fill tube flare nut and remove the
bolt (1), ground strap (2) and serrated flange nut (3)
from the fill tube bracket. Remove the bracket (4).

G1523MP

Remove the lock nuts and flat washers from the

three transmission and transfer case mounting bolts.
Remove the bolts.

PRINTED IN U.S.A. 501-6 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 29 STEP 31

1 2

3
G1440MP G1441MP

To find the balance point for the transmission/transfer
case assembly, raise the hoist 2 inches while
watching the three mounting brackets.
If the three mounting brackets do not lift evenly the
same distance proceed to Step 30.
If the three mounting brackets raise evenly the same
distance, proceed to Step 31.
Lower the assembly onto the three frame mounting
pads and install stabilizer chains between the hoist
and the hydraulic pump mounting stud (1) and, the
hoist and the transfer case split line flange (2) or the
engine bell housing (3).
STEP 32

STEP 30

1
G1522MP
Raise the transmission/transfer case assembly
slowly and move to the right just enough for the Left
side mounting brackets (1) to clear the wire
harnesses and hydraulic hoses.
G1440MP

Lower the transmission/transfer case assembly onto

the three frame mounting pads and change the lift
point of the load rotor.

G1443MP
Raise the assembly until the bottom of the
transmission clears the frame and move the
assembly out the right side of the machine.
PRINTED IN U.S.A. 501-7 907871/AP0998
Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
TRANSFER CASE REMOVAL STEP 35

STEP 33

2
1
G1493MP

2 Turn the transmission pump shaft until the drive plate

G1452MP
to torque converter mounting bolts are visible in the
top opening of the transmission bell housing.
Place the transmission and transfer case assembly
on a level work surface with the bottom of the Remove the eight mounting bolts.
transmission (1) on the surface and blocking under
the three mounting brackets (2). STEP 36
Remove the lifting rings or brackets. 1

STEP 34
2
1

G1453MP

Mark the position of the bell housing on the

transmission (1) for alignment during reassembly.

G1453MP
Remove the transmission bell housing mounting
bolts (2).
Install a lifting ring (1) in the transfer case split line
flange where the hose and wire harness P-clamp
was removed. Install a lifting ring (2) in the engine
bell housing as shown.

Attach the chains from the load rotor and hoist to the
lifting rings. Raise the hoist until the chains are
supporting, but not lifting, the weight of the transfer
case.

PRINTED IN U.S.A. 501-8 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 37 TORQUE CONVERTER REMOVAL

1 STEP 38
1

G1451MP

Slowly and carefully separate the transfer case from 2

the transmission. The torque converter (1) should G1446MP
stay on the transmission if possible.
To r e m o v e t h e t o r q u e c o n v e r t e r f r o m t h e
transmission, support the weight as the torque
converter is pulled off the transmission input shafts
(1).
2 NOTE: There is transmission fluid inside the torque
converter that will spill out the hub (2) if the hub is
tilted downward.

G1445MP

3
G1444MP

NOTE: If the torque converter comes off with the

transfer case, the torque converter centering shaft
(2) is stuck in the transfer case drive plate alignment
sleeve (3).

Support the torque converter until it can be removed

from the transfer case.

PRINTED IN U.S.A. 501-9 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
TORQUE CONVERTER STEP 40
INSTALLATION 2
1
STEP 39

2
1

G1448MP

3 3
G1446MP

Align the hub (1) of the torque converter with the 4

input shaft (2) of the transmission. Slowly rotate the
converter as it is installed on the input shafts (2). Do
not force the converter on the shaft, it will slide on
freely as the splines of the input shafts (2) align with
the splines in the torque converter.

The converter is fully seated on the transmission

when the transmission pump drive lugs (3) are
engaged in the transmission.
G1447MP

To check the torque converter for correct installation

on the transmission, measure the distance between
the transfer case drive plate (1) and the bell housing
mounting flange (2). The distance between the
torque converter flex plate (3) and the tranmission
mounting flange (4) must be equal to or less than
between the drive plate (1) and bell housing
mounting flange (2).

If the measurement between the flex plate (3) and

mounting flange (4) is larger than between the drive
plate (1) and bell housing mounting flange (2), repeat
Steps 38 and 39 until the torque converter is fully
seated on the transmission.

PRINTED IN U.S.A. 501-10 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
TRANSFER CASE INSTALLATION STEP 43

STEP 41

G1444MP

G1445MP

Apply a thin layer of anti-seize compound on the

torque converter centering shaft. 2

STEP 42

G1451MP
Use the hoist and load rotor to align the transfer case
2 drive plate alignment sleeve (1) and the torque
1 converter centering shaft (2). Install the transfer case
on the transmission.

G1490MP
STEP 44
Install lifting rings to the split line flange (1) and 1
engine bell housing (2) as shown. Attach a load rotor
and hoist to the lifting rings.

2
4

G1453MP
Use the load rotor to tilt the transfer case and align
the bell housing (1) on the transmission (2). Apply
Loctite 242 Threadlock (or equivalent) to the threads
of the 3/8 x 1 1/4 inch Grade 5 bell housing mounting
bolts (3). Install and tighten the mounting bolts to a
torque of 33 to 37 lb ft (45 to 50 Nm).

NOTE: Do not tighten the top bolt (4) at this time.

PRINTED IN U.S.A. 501-11 907871/AP0998
Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 45 STEP 47

G1493MP G1438MP

Rotate the transmission pump drive shaft until the

drive plate mounting hole is visible in the opening on
the top of the bell housing. Hold the drive plate from
turning and continue to rotate the pump drive shaft
until the torque converter flex plate mounting holes
align with the drive plate holes.

Apply Loctite 242 Threadlock (or equivalent) to the

threads of the 3/8 x 1 inch NF Grade 5 bolts. Install,
but do not tighten, the eight mounting bolts. When all 2
eight bolts are installed tighten the bolts to a torque
of 33 to 37 lb ft (45 to 50 Nm).

STEP 46 G1494MP

Use M12 x 25 Grade 10.9 bolts to install lifting rings

or brackets on the front left and front right mounting
holes (1) of the transmission.

NOTE: If using lifting rings with only one bolt each,

mount the rings in the lower holes (2).

STEP 48

G1452MP

Place support blocking under the three mounting

brackets and remove the chains and lifting rings.

G1496MP

Install a load rotor between the lifting rings or

brackets and a hoist.

PRINTED IN U.S.A. 501-12 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 49 STEP 51

G1443MP

Raise the transmission/transfer case assembly high

enough for the bottom of the transmission to clear
the top of the right side frame rails. Move the
assembly into position over the three frame to
transmission and transfer case mounting brackets.

STEP 52

1
2

G1496MP

To find the balance point for the transmission/transfer

case assembly, raise the hoist 2 inches and adjust
the load rotor.
G1439MP
STEP 50 Hold the wire harnesses and hoses (1) on the left
side of the transmission clear of the transmission and
1 transfer case mounting brackets (2). Slowly lower the
the assembly onto the frame brackets.
2

G1497MP

Lower the transmission/transfer case assembly onto

the support blocks and install stabilizer chains
between the hoist and the hydraulic pump mounting
stud (1) and the hoist and engine bell housing (2).

PRINTED IN U.S.A. 501-13 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 53 STEP 54

2
3
G1430MP G1441MP

Remove the chains, hoist and lifting rings or

brackets.

STEP 55

1 1
3
2
3

G1431MP 2

4
G1432MP

Install the fuel fill tube bracket (1). Install and tighten
1 the fill tube flare nut on the filler cap adapter. Install
the 3/8 x 1 1/2 inch Grad 5 bolt (2), ground strap (3)
and serrated flange nut (4). Tighten the bolt and nut
to a torque of 33 to 37 lb ft (45 to 50 Nm).

3 2

G1523MP

Install the three 3/4 x 4 inch Grade 5 bolts (1) large

flat washers (2) and lock nuts (3) in the mounts.

NOTE: The left side transfer case mount flat washer

(2) has a cut out for clearance during installation.
Tighten the bolts and nuts to a torque of 285 to 320 lb
ft (385 to 435 Nm).

PRINTED IN U.S.A. 501-14 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 56 STEP 58

2
1
2
1
1
3
4 5

3
3
5
G1427MP G1423MP
Install the P-clamp (1) on the transmission fill tube Use two M12 x 25 Grade 8.8 bolts (1) to install the
(2). Use a 3/8 x 1 1/4 inch Grade 8 bolt (3), lock starter relay mount (2) and the ground wires (3) to
washer and nut to install the tube and P-clamp on the the transmission. Tighten the bolts to a torque of 40
transfer case. Tighten the bolt and nut to a torque of to 45 lb ft (54 to 61 Nm).
46 to 52 lb ft (63 to 71 Nm).
STEP 59
Secure the horn wire harness (4) to the fill tube with
cable ties (5). 4
2
STEP 57
3

G1422MP

Install the large P-clamp (1) over the engine wire

harness (2) and fuel hoses (3). Remove the top
transmission bell housing bolt (4). Apply Loctite 242
G1428MP Threadlock (or equivalent) to the threads of the bolt.
Install a new transmission filter. Use the bolt (4) to install the P-clamp (1) on the
transmission bell housing mounting flange. Tighten
the bolt to a torque of 33 to 37 lb ft (45 to 50 Nm).

PRINTED IN U.S.A. 501-15 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 60 STEP 62

2
3
1

G1421MP G1426MP
Use the M12 x 25 Grade 8.8 bolt to install the wire Install and tighten the transmission fill tube (1) on the
harness ground wire to the left side of the front of the transmission. Use a cable tie (2) to
transmission. secure the fuel hose (3) to the fill tube.

STEP 61 STEP 63

4 1

1
3

G1420MP
Install the transmission control wire connector (1)
and the transmission fluid temperature sender wire
(2) on the transmission. Connect the reverse
pressure switch wire connector (3) to the main frame
wire harness (4).
G1425MP
Apply Loctite 242 Threadlock (or equivalent) to the
threads and use the four 3/8 x 1 3/4 NF Grade 8 bolts
(1) to install the front drive shaft on the transmission
output yoke. Tighten the bolts to a torque of 36 to 46
lb ft (49 to 62 Nm).

PRINTED IN U.S.A. 501-16 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 64 STEP 66

2
G1424MP G1419MP

Apply Loctite 242 Threadlock (or equivalent) to the
threads and use the four 3/8 x 1 3/4 NF Grade 8 bolts
(1) to install the rear drive shaft on the transmission
rear output yoke. Tighten the bolts to a torque of 36
to 46 lb ft (49 to 62 Nm).
NOTE: Be sure the transmission drain plug (2) is
installed and tightened.
Install the engine and transmission covers hinge
mounting bracket between the engine and
transmission. Use the three 3/8 x 3/4 inch Grade 5
bolts and washers on the front and three rear bolts
and washers to install the bracket to the main frame.
Tighten the bolts to a torque of 33 to 37 lb ft (45 to 50
Nm).
STEP 67

STEP 65
2

3
5
4

G1418MP
Install the transmission cover (1) on the three hinge
studs (2). Install internal star lock washers and 5/16
G1442 inch nuts (3) on the hinge studs (2). Tighten the nuts
Install and tighten the transmission cooler hose. to a torque of 12 to 13.5 lb ft (16.4 to 18.4 Nm).

Install the rod end (4) of the lift assist cylinder on the
ball stud (5).

PRINTED IN U.S.A. 501-17 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 68 STEP 71
1

1 2
G1417MP G1415MP

Install the wire retaining pin in the ball socket and clip
the loop (1) of the pin around the groove (2) in the
neck of the ball socket.
STEP 69
Use two 5/16 x 3/4 inch flanged socket bolts (1) and
one 5/16 x 3/4 inch Grade 5 bolt (2) flat washers and
serrated flange nuts to install the front grille brace
(3). Tighten the bolts to a torque of 12 to 13.5 lb ft
(16.4 to 18.4 Nm).

STEP 72
1

G1413MP

Install the horn wire harness on the horn (1) and

G1412MP
secure the wire harness to the horn bracket with a
cable tie (2). Use five 1/4 inch serrated flange nuts to install the
radiator grille. Tighten the nuts to a torque of 9 to 10
lb ft (12.2 to 13.7 Nm).
STEP 70

2
1

G1416MP

Use three 1/4 inch serrated flange nuts (1) to install

the front grille (2) on the cover hinge bracket. Tighten
the nuts to a torque of 9 to 10 lb ft (12.2 to 13.7 Nm).

PRINTED IN U.S.A. 501-18 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift POWER TRAIN
STEP 73

G1401MP
See Section 602, Hydraulic Pump Removal and
Installation section of this manual for the correct
procedure to install the hydraulic pump.

STEP 74
See Section 101 of this manual for the specified
transmission fluid, and correct fluid level.

Fill the transmission with 12 quarts (11.4 Liters) of

the specified fluid.

STEP 75

G1393MP
See Section 201, Engine Removal and Installation
section of this manual for the correct procedure to
install the engine.

PRINTED IN U.S.A. 501-19 907871/AP0998

 INTENTIONALLY BLANK

907871/BP1108 501-20 PRINTED IN U.S.A.

 Section
502

TRANSFER CASE REPAIR

DL Series Dynalift

907871/AP0998
PRINTED IN U.S.A.
Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information

SPECIFICATIONS
Input and Output Shafts End Play ...............................................................0.003 to 0.005 inch (0.076 to 0.127 mm)

Driven Gears Shaft End Play.......................................................................0.003 to 0.005 inch (0.076 to 0.127 mm)

Oil Type .....................................................................................................................................S.A.E. 40W Motor Oil

Transfer Case Oil Capacity...................................................................................................2.75 U. S. Quarts (2.6 L)

TORQUE VALUES
U.S. Value Metric Value

Engine and Transmission Bell Housing Mounting Bolts ............................... 80 to 112 lb ft ...........122 to 154 Nm

Driven Gear Bearing Retainer Bolts .............................................................. 21 to 26 lb ft ..............28 to 35 Nm

Transfer Case Housing Split Flange Bolts and Nuts ..................................... 46 to 52 lb ft ..............62 to 71 Nm

Transfer Case Mounting Bracket Bolts ........................................................ 160 to 180 lb ft ..........215 to 245 Nm

PRINTED IN U.S.A. 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift TRANSFER CASE
TRANSFER CASE REPAIR
TRANSFER CASE DISASSEMBLY STEP 3
1 2
STEP 1

G1450MP

Remove the two mounting brackets (1) from the

transfer case. Use a dye marker to mark the position
G1441MP
of each bell housing (2) in relation to the gear case.
Remove the transmission and transfer case from the
machine. See Section 501, Transmission and Remove the breather and elbow fitting (3) from the
Transfer Case Removal section of this manual for the front housing.
correct removal procedure.

STEP 4
STEP 2

G1491MP
G1492MP Place the transfer case on a level work surface with
Remove the bottom plug and drain the fluid from the the input and output shafts facing up. Use a dye
transfer case. marker to mark the location of the two bearing
retainers (1) in relation to the housing for assembly
reference.

NOTE: Some fluid trapped inside the transfer case

may leak out the breather hole.

PRINTED IN U.S.A. 502-1 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift TRANSFER CASE
STEP 5 STEP 8

2
G1506MP G1477MP
Use an internal bearing puller to remove the Remove the six bolts (1) from the transmission bell
alignment sleeve from the drive plate hub. housing (2). Remove the bell housing and the
bearing adjusting shims. Retain the shims with the
STEP 6 bell housing.

STEP 9

2
1 1
2

G1487MP
Remove the external snap ring (1) from the output
shaft. Lift and remove the drive plate (2) from the
G1478MP
output shaft.
Remove the six bolts (1) from the engine bell housing
(2). Remove the engine bell housing and the bearing
STEP 7 adjusting shims. Retain the shims with the bell
housing.

STEP 10

G1479MP

Remove the key from the output shaft.

G1468MP

PRINTED IN U.S.A. 502-2 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift TRANSFER CASE
Remove and discard the o-rings from the engine and STEP 13
transmission bell housing pilot flange.

STEP 11

1
2

G1454MP

Raise the hoist only enough to suspend the transfer

G1505MP
Remove the six bolts (1) from each driven gear
bearing retainer (2) and remove both retainers.
Retain the bearing adjusting shims with each bearing
retainer.
case weight from the chains. If the transfer case
housings do not separate, the RTV sealant between
the flanges is holding them together. It may be
necessary to pry the two halves of the housing apart.
Clean the RTV sealant from both housing split line
flanges.

STEP 12
STEP 14
3
3
1

3 2 1
G1470MP
G1463MP
Drive the two dowel pins (1) out of the top flange.
Remove the remaining housing flange bolts (2), lock To remove the bearing cups from the shaft housing
washers and nuts. Use three of the 1/2 x 1-1/2 inch use a 2 7/8 inch (73 mm) bearing driver to push the
bolts (3) and lock washers (removed during cups out of the housing.
disassembly) to install lift rings and chains on the
transfer case housing as shown.

PRINTED IN U.S.A. 502-3 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift TRANSFER CASE
STEP 15 STEP 18

G1464MP G1459MP

If necessary, use an internal bearing puller to remove If necessary, use a split flange bearing puller to
the bearing cups from the engine and transmission remove the bearing cones from both sides of each
bell housings. gear assembly.

STEP 16 STEP 19
1 2 3 4

G1469MP G1466MP

Remove the input gear (1), two driven gears (2) (3)
and the output gear (4) assemblies from the front
housing. Mark the four gears for reassembly location.

1
STEP 17

G1467MP

Use a bearing or seal driver to push the input or

output shaft seals out of the engine (1) and
transmission (2) bell housing.

G1457MP
STEP 20
If necessary, use an internal bearing puller to remove Clean and inspect all parts for excessive wear or
the four bearing cups from the front housing. damage. Replace any worn or damaged parts.

PRINTED IN U.S.A. 502-4 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift TRANSFER CASE
TRANSFER CASE ASSEMBLY STEP 23

STEP 21

G1462MP

If removed, use a 2 7/8 inch (73 mm) bearing driver

to install the four bearing cups into the front housing.
G1460MP

Press the bearing cone on the gear shaft until they

are seated firmly against the shoulder of the gear. STEP 24

STEP 22

G1465MP

If removed, use the bearing driver to install the

bearing cups in the engine and transmission bell
G1461MP
housing.
Repeat Step 21 for each gear and bearing set.

NOTE: Coat all bearing cones and cups with clean

specified gear lube.

PRINTED IN U.S.A. 502-5 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift TRANSFER CASE
STEP 25 STEP 27
1 2 3 4

G1455MP G1473MP

Lubricate the bearings and install the input (1) two Use three 1/2 -13 NC x 1-1/2 inch, Grade 8, engine
driven (2) (3) and output (4) gear assemblies in the and transmission bell housing bolts, to install lift rings
front housing. to the rear housing.

Install the two dowel pins in the front housing so they Attach chains to the lift rings and a hoist. Adjust the
extend upward from the housing flange. chains until the housing is level when raised.

STEP 26 STEP 28
1

2
G1469MP G1454MP

Apply a continuous 1/8 inch (3.2 mm) bead of Align and install the housing (1) on the dowel pins
Permatex RTV Silicone Gasket Maker (or equivalent) and the front housing (2).
on the front housing flange.

PRINTED IN U.S.A. 502-6 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift TRANSFER CASE
STEP 29 STEP 31
4 2
1
3
2
2
1
4

2
G1470MP G1474MP

Install the 3/8 -16 NC x 1-1/4 Grade 8 bolts (1), lock
washers (2) and nuts (3) in the housing split line
flange. Tighten the bolts alternately and evenly
starting with the middle two bolts (4) and working
towards each end. Tighten the bolts to a torque of 46
to 52 lb ft (63 to 71 Nm).
Install the driven gear bearing retainer (1). Install
three of the 5/16 -18 NC x 1 inch Grade 5 retainer
bolts (2) in the retainer as shown. Finger tighten the
bolts, then evenly tighten the bolts to a torque of 10
in. lb (1.14 Nm). Rotate the gears several revolutions
in both directions to completely seat the bearings.
Retorque the bolts if necessary.

STEP 30 STEP 32

G1471MP G1472MP
Lubricate the bearings and use a 2 7/8 inch (73 mm) Bearing must be adjusted so that there will be 0.003”
bearing driver to install the two driven gear bearing to 0.005” end clearance on all shaft bearings. Use a
cups in the housing. feeler gauge to measure the gap between the
bearing retainers and the housing at all three bolt
locations to get an average nominal measurement.
Example:
0.052” + 0.050” + 0.054” = 0.156 “ = 0.052”
3 3
Select a shim pack equal to the average total gap
measurement plus 0.003” to 0.005” for the specified
bearing end clearance.
Example: 0.052 + 0.004 = 0.056 = shim pack
NOTE: The shims are selective and color coded as
follows: Blue = 0.005”, Silver = 0.007” and
yellow = 0.020”. Measure each shim
individually to get an accurate bearing
setting.
PRINTED IN U.S.A. 502-7 907871/AP0998
Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift TRANSFER CASE
STEP 33 STEP 35

1
G1482MP G1505MP

Remove the bearing retainer. Apply a 1/8 inch (3.2
mm) bead of Permatex RTV Silicone Gasket Maker
(or equivelant) to the radius of the retainer pilot
flange as shown.
Align and install the bearing retainer (1) on the
housing. Use Loctite 242 Thread Lock (or equivelant)
on the threads of each bearing retainer mounting bolt
(2). Install and tighten the bolts (2) alternately and
evenly to a final torque of 21 to 26 lb ft (28 to 35 Nm).

STEP 34 Repeat Steps 31 through 35 for the opposite driven

gear bearing retainer adjustment.

IMPORTANT: Rotate the gears after each bearing

adjustment. There must be no bearing lockup or
binding.

STEP 36

G1483MP

Install the selected shim pack on the bearing

retainer.

NOTE: To aid in shim pack and bearing retainer

alignment during installation, 5/16” x 3 inch
NC pilot studs installed in opposite holes of
the housing may also be used. G1475MP

Use three 1/2 -13 NC x 1-1/2 inch Grade 8 bolts in

both the engine bell housing and transmission bell
housing and repeat the procedure outlined in Steps
31 and 32 for measuring for the correct shim pack.

IMPORTANT: Be sure the O-ring is removed from

the bell housing pilot.

PRINTED IN U.S.A. 502-8 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift TRANSFER CASE
STEP 37 STEP 39

2
G1468MP G1477MP

Lubricate and install new o-rings in the groove of the

transmission and engine bell housing bearing
retainer pilots. 1

STEP 38

G1478MP

Install the engine (1) and transmission (2) bell

housing on the shaft housing in the position marked
at disassembly. Apply Loctite 242 Threadlock (or
equivalent) to the bolt threads and install the six 1/2 -
G1484MP
13 NC x 1-1/2 Grade 8 bolts (3) in each bell housing.
Install the selected shim packs on the housing. Use Tighten the bolts alternately and evenly to a torque of
pilot studs for alignment.. 80 to 112 lb ft (122 to 154 Nm).

PRINTED IN U.S.A. 502-9 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift TRANSFER CASE
STEP 40 STEP 42

G1486MP G1480MP

Apply a thin film of Lubriplate No. 105 Assembly Align and install the drive plate (1) on the output shaft
Grease to the inside lip of the new input and output (2) and key (3).
shaft seals.

Apply a thin film of Loctite 609 Advhesive to the STEP 43

outside diameter of the seals.
Install the seals on the shafts and use a 3 inch (76
mm) seal driver to seat the seals into the bell
housing. The top (1) of the seal must be flush with
the face (2) of the bell housing.

STEP 41

G1487MP

Install the snap ring on the output shaft.

STEP 44

G1479MP

Install the key in the output shaft.

G1444MP

Install the alignment sleeve in the hub of the drive

plate.

PRINTED IN U.S.A. 502-10 907871/AP0998

Template Name: OML_2_col 907871 Alt= to hide template information
Template Date: 1994_04_22 Alt+ to display template information
DL Series Dynalift TRANSFER CASE
STEP 45 STEP 47

1
1

2 2
G1490MP G1451MP

Use the four 5/8 NC x 1 1/4 inch Grade 5 bolts (1) to
install the transfer case mounting brackets (2) on the
front housing. Tighten the bolts (1) to a torque of 160
to 180 lb ft (215 to 245 Nm).
Install the elbow fitting and breather (3) on the front
housing.
STEP 46
See Section 501, Transmission and Transfer Case
Installation section of this manual for the correct
procedure to install the transfer case on the
transmission and to install the transmission/transfer
case assembly into the machine.
STEP 48
1

2
G1503MP

Remove the breather cap (1) from the top of the

G1492MP
transfer case. Fill the case through the breather
Install and tighten the drain plug.
elbow adapter (2) with 2.75 quarts (2.6 L) of the
recommended fluid.

Install and tighten the breather cap.

PRINTED IN U.S.A. 502-11 907871/AP0998