Lull 944E-42 Service Manual - Manual (Page 199)

6.23 Model 644E-42/944E-42 Rev. 6/04
Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4
6.12.10 Internal Transfer Case Repair
Detailed transfer case service instructions covering
repair, disassembly, reassembly, adjustment and
troubleshooting information are provided in the ZF Model
TB92-I4 Transfer Case Operating and Repair Manual,
JLG P/N 8990495
(ZF part number 5871.134.002).
6.12.11 Transfer Case Installation
1. Secure the transfer case to a suitable lifting/
supporting device and position the transfer case
beneath the engine support structure. Raise the
transfer case into position under the engine support
structure, (make certain that the alignment dowel pin
is located in the correct transfer case hole (9).
2. Align the dowel pin (9) of the transfer case with the
hole of the transmission (11), and also the input spline
of the transfer case with the output shaft (10) of the
transmission. Carefully press the transfer case onto
the output shaft until the mating surfaces of both the
transfer case & transmission meet.
3. Install twelve (7) capscrews (short) into the rear
transfer case mounting holes by hand. Torque each of
the capscrews to 140 lb-ft (190 Nm).
4. Install two (8) capscrews (long) into the transmission
holes by hand. Torque each of the capscrews to
140 lb-ft (190 Nm).
5. Refer to Section 5.4.4, “Drive Shaft Installation,”
procedures for re-installing the drive shafts to the
transfer case.
6. If the vehicle has dual batteries, connect both
negative battery cables (12 and 13) to both
batteries.
Connect the lower negative battery cable (12) to the
negative (-) terminal on the lower battery (14). Swing
the upper battery box (15) in and make sure that the
lip (16) on the upper battery box slides below the
knob (17). Secure in place with the knob (17).
MU0650
12
13
14
15
16
17