26 Dealer Service
MAN0224 (Rev. 7/29/2005)
SEAL REPAIR
(ON CAST/CROWN TOP GEARBOX - S/N
1162806 AND ABOVE ONLY)
(Figure 13)
Vertical Shaft Seal Repair
1. Disconnect and remove the rear driveline from the
gearbox.
2. Remove vent plug (9) and siphon gear lube from
housing through this opening.
3. Remove crossbar (see Crossbar Removal, page
28).
4. Remove output cap (17) and output seal (16) by
removing four cap screws (13) and washers (12).
Replace with new seal (see Seal Installation,
page 22).
Vertical seal should be recessed in output cap.
NOTE: Distortion to seal cage or damage to seal
lip will cause seal to leak.
5. Secure output cap (17) on to bottom of gearbox
using four cap screws (13) and lock washers (12).
NOTE: Make sure output gasket (10) and (11) are
in place.
6. Fill gearbox with SAE 80W or 90W gear lube until it
runs out the side level plug.
7. Remove and replace any seal damaged in
installation.
Horizontal Seal Leak Repair
1. Disconnect and remove the rear driveline from the
gearbox.
2. Remove vent plug (9) and siphon gear lube from
housing through this opening.
3. Remove input seal (4). Replace with new one
(refer to Seal Installation, page 22).
4. Fill gearbox with SAE 80W or 90W gear lube until it
runs out the side level plug.
Figure 13. Cast/Crown Top Gearbox Assembly
1. Housing
2. Inspection cover
3. 22 Tooth gear
4. Input seal
5. Input shaft
6. Retaining ring
7. Gear spacer
8. Retaining ring
9. M18 x 1.5 Vent plug
10. Output gasket (0.30)
11. Output gasket (0.13)
12. Lock washer
13. M10 x 1.5 x 25 Cap screw
14. 1" - 14 Slotted flange nut
15. Cotter pin
16. Output seal
17. Output cap
18. Output bearing spacer
19. 15 Tooth output shaft & pinion
20. Ball bearing 208
21. Ball bearing 207
22. Sealing washer
23. Lock washer M8
24. M8 x 1.5 x 25 Cap screw
(Rev. 4/4/2011)
