Service Manual J340-S, J380-S, J400-S, W460-S

5.063"
1.906"
3.218"
5.281"
2.593"
1.187"
45
1.96"
3.78 DIA.
.917"
4.625"
2.141"
9.843"
3.968"
2.290"
25
3.052"
4.063"
7.531"
4.000"
3.468"
.323"
23.292mm
117.475mm
49.784mm
54.381mm
58.166mm
250.012mm
100.787mm
8.204mm
101.600mm
88.087mm
191.287mm
103.200mm
77.520mm
65.862mm
134.137mm
30.149mm
81.737mm
128.600mm
48.412mm
96.012mm
spacer. Use a thinner spacer to decrease end play or a
thicker spacer to increase end play. Any preload on the
gear bearing will cause premature bearing failure.
11 . Assemble bearing cones onto front and tear of input gear
and install input gear assembly into intermediate case.
Rotate to make sure it is seated properly.
12 . Assemble shift fork onto shift collar and install into
intermediate case. Be sure the boss on the shift fork is
pointing up or towards the inter-axle differential before
installing. Unit will not shift correctly if installed improp-
erly.
13 . Apply Loctite #290 to threads of shift fork shaft.
INTERMEDIATE CASE ASSEMBLY
FABRICATE SPECIAL PLATE FROM 3/8” STEEL
26
14 . Install shift fork shaft into intermediate case and thread
into shift fork. Torque shaft to 30 to 38 Lb- Ft (41-52 N-
m). Place spring over shaft. Compress spring and install
retainer clip into groove in shaft. Intermediate case is now
ready for assembly of inter-axle differential.
Intermediate Case Assembly Complete