Lull 944E-42 Service Manual - Manual (Page 200)

Transmission: ZF 4WG-92/98 TSC & Transfer Case: ZF TB92-I4
6.24 Model 644E-42/944E-42 Rev. 6/04
6.13 TROUBLESHOOTING
This section provides an easy reference guide covering
the most common problems that occur during operation
of the transfer case.
Note: Contact your local Lull distributor or the JLG
Service Department at (877) 554-5438 or
(717) 485-6657, if internal transfer case repair is
required during the warranty period.
Detailed transfer case service instructions covering repair,
disassembly, reassembly, adjustment and troubleshooting
information is provided in the ZF Model TB92-I 4 Transfer
Case Operating and Repair Manual, JLG P/N 8990495
(ZF part number 5871.134.002).
The transfer case should be checked, serviced and
repaired only by experienced service technicians who are
aware of all safety instructions and particular component
features.
6.13.1 Transfer Case Troubleshooting
Problem Cause Remedy
1. Excessive transfer case
noise.
1. Oil level too low.
2. Transfer case filled with
incorrect oil.
3. Excessive bearing “end play.”
4. Worn or damage bearings.
5. Worn or broken gear teeth.
6. Contamination in the transfer
case.
7. Incorrect assembly of parts.
1. Fill oil to correct level (Refer to
Section 2.5.10, “Fluid and
Lubricant Capacities.”)
2. Drain transfer case and fill to
correct level with Universal
Tractor Fluid (Refer to Section
2.6.7, a. “Transfer Case Fluid.”)
3. Check bearing end play and
correct with shims as needed.
4. Replace bearings as needed.
5. Replace gears as needed.
6. Check for foreign particles.
7. Check assembly of transfer
case components.
2. Oil leaking from transfer case. 1. Breather blocked.
2. Plugs or fittings loose.
3. Incorrect oil level.
4. Gaps in sealant between
housing halves.
5. Worn, damaged or improperly
seated seals and/or worn or
damaged input/output shaft
sealing surfaces.
6. Damaged housing.
1. Clean or replace breather.
2. Tighten plugs and fittings.
3. Fill oil to correct level (Refer to
Section 2.5.10, “Fluid and
Lubricant Capacities.”)
4. Clean housing mating surfaces,
apply new sealant (Loctite
®
518)
and torque housing capscrews
to 34 lb-ft (46 Nm).
5. Replace seals and/or input/
output gear assemblies as
needed.
6. Replace housing.