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Atlas Service Manual

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1. gt Figure 29 exploded view shift rail housing 39 Procedure 1 Apply spray lubrication to the inner bore of the shift rod detent holes as shown Figure 30 2 Install lockout pills 300388 into previously lubricated holes 3 Install front shift rail 300382 into shift rail housing as shown Critical Ensure that the three detent slots on the shift rail face the holes where detent balls and springs are installed Allign Shift Detent Figure 31 4 Position the front shift rail in the neutral shift position middle slot This will allow installation of rear shift rail 5 Install rear shift rail 300381 into shift rail housing Critical Ensure that the three detent slots on the shift rail face the holes where detent balls and springs are installed 6 Position the shift rail housing so that the shift detent holes face up 7 Install shift detent ball 300392 into each detent hole of shift housing 40 10 11 12 13 14 15 Install shift detent spring 300390 into each detent hole of shift housing Ensure that each spring touches each detent ball Apply assembly lubrication into shift detent holes of shift housing Apply assembly lubrication on each shift detent o ring 300482 Install shift detent o rings 300482 on each shift detent plug 302019 Install each shift detent plug 302019 with inch socket Torque to 12 lb ft Install shift housing freeze plugs 300389 in shift housing
2. ARBOR PRESS PNEUMATIC IMPACT GUN PNEUMATIC IMPACT GUN TORQUE WRENCH 1 TORQUE WRENCH 2 DEPTH MICROMETER RATCHET WRENCH RETAINING RING PLIERS RETAINING RING PLIERS 2 RETAINING RING PLIERS 3 SOCKET EXTENSION DEAD BLOW HAMMER SEAL REMOVER HEAD STYLE DESCRIPTION 2 TON MIN CAPACITY LIGHT DUTY IMPACT FOR DISASSEMBLY HEAVY DUTY IMPACT FOR DISASSEMBLY 3 8 DRIVE 5 50 FT LB TORQUE RANGE eles DRIVE 150 FT LB MIN TORQUE CAPACITY USED ON ATLAS PRIOR TO SERIAL 10550 je IMPACT SOCKET EXTERNAL RETAINING RING PLIERS 35MM MIN CAPACITY 100 MAX TIP DIAMETER INTERNAL RETAINING RING PLIERS 7OMM MIN CAPACITY 125 MAX TIP DIAMETER EXTERNAL CONSTANT SECTION RETAINING RING PLIERS STRAIGHT TIP 1 3 4 CAPACITY Figure 62 LOCATION OF USE BEARINGS SHAFTS AND SEALS VARIOUS FASTENERS YOKE NUT REMOVAL VARIOUS FASTENER ASSEMBLY YOKE NUT ASSEMBLY OIL PAN BOLTS BHCS T40 TORK OIL PAN BOLTS REAR BEARING CAP SHIFT FORK RETAINING SCREWS CLUSTER SHAFT RETAINING BOLTS aoe PLUG 4WD SWITCH USED TO START ALL FASTENERS INPUT GEAR RETAINING RING INSTALLATION INPUT BRG RETAINING RING INSTALLATION MARRIED SETUP ONLY SPEEDOMETER WORM GEAR 2 asss Las RING MSAN E I AD BENER TO INSTALL ESS FORK 55 GENERAL ASSEMBLY DISASSEMBLY REMOVAL OF LIP STYLE OIL SEALS 63
3. e Divorced mount 25 Front output sub assembly The part number listed in the exploded view are an example of one assembly your application may require different part numbers Tools required SST 104 SST 105 SST 100 Arbor press Snap ring pliers TE AR NO NUMBER 300102 z 1500125 3 20 DESCRIPTION D A cee UUS U 4 500354 a 1300507 JI It 20 IGE Z gt A WA T3 0051 il CONS GIGS BEARING ATLAS MSG610 TAPERED AC INC ASSEMBLY WASHER ATT AS FRONT TOW SPEED GEAR BEARING ATLAS M86649 TAPERED ROLLER m a 4 Ingo dened x H gt m gt PLIN SAIF CA BEARING jt DO ATLAS SYNCHRO e AS OW SPEED ASSEMBLY REAR RIN ATLAS FRON OU MEI Y mint NINJA Ll i NG A LAS JZ0 Figure 10 front output exploded view 26 Procedure 1 Start by installing bearing race 300513 into retainer casting 300103 Press bearing race into housing with special service tool SST 104 Ensure bearing race is fully seated into housing Figure 11 2 Press front output yoke seal into housing with SST 104 3 Position front output shaft 300123 as shown and install synchro slider 300371 on to shaft Figure 12 4 Position shaft as shown and install synchro slider over the synchro hub 5 Use thu
4. inch socket Reposition case on workbench to access rear side of front output Clean case with solvent and rag in the area where the front output bearing retainer 300105 mates to case 47 Front output preload adjustment a Measure rear bearing retainer depth D using depth micrometer 0 130 3 302mm is the nominal depth Figure 41 b Measure bearing race height H from main housing using depth micrometer 48 Figure 42 measurement of bearing race height c Factory preload specification 0 000 0 0015 0 000 0 038mm At 65 80 F 18 27 C d Example preload calculation Bearing retainer depth D 0 130 3 302mm Bearing race height H 0 113 2 870mm Desired preload P 0 001 0 025mm Equation D H P required thickness of shims Calculation 0 130 0 113 0 001 018 457mm Required thickness of shims e Choose from available shims to construct calculated thickness Available shims 0 010 0 254mm 0 008 0 203mm 0 0045 0 114mm Figure 43 49 f Place shims in bearing housing and measure depth with depth micrometer verify correct thickness of shims Figure 44 depth measured with shims installed 20 Apply continuous bead of silicon to mating surface of front output bearing retainer as shown Figure 45 21 Install LocTite 518 on four retaining bolts new bolts 2014 do not require Install bolts by hand with 5 16 inch socket Torque to 25 lb ft D
5. Specifications All Atlas Il transfer cases are shipped dry All holes are plugged with red plastic caps to keep contaminates out during shipment Preferred lubricant Amsoil MTG GL 4 or any synthetic 75W 90 meeting GL 4 standards Capacity Quarts 2 0 Liters 1 98 The Atlas includes a site tube to help you determine the correct fluid level Once the required two quarts are installed we recommend marking the oil level on the site tube A small zip tie or hose clamp works well for this In 2014 the site tube was removed from the case Operation Temperatures Normal Operating Temperature 160F 220F Degrees Max Intermittent Temperature 220F 240F Degrees Lubrication Notes Too much fluid will cause foaming at high speeds Foaming oil expands and fills the entire cavity which forces fluid out the breather tube or the breather hose may be restrictive causing the Atlas to build up pressure Advance Adapters recommends a minimum of three feet of 3 8 fuel hose for proper ventilation This hose should be connected to the brass elbow located on top of the Atlas Rear shift block Your warranty could be voided if the proper gear lubricants are not used and proper oil levels are not maintained 10 Maintenance Lubricant should be changed 5000 miles first time Every 15000 miles thereafter Re torque fasteners Check bolt torque on adapter to the Atlas and yokes 1 time 5000 miles 2 time 15000 miles same time as oi
6. housing assembly 2 Remove six 1 4 inch Allen head bolts 723730 retaining tail housing 300104 to case 3 Remove tail housing 300104 from output shaft 4 Remove rear output shim 300491 from output shaft 5 Remove speedometer gear 300625 from output shaft 6 Remove snap ring 300627 from output shaft 7 Remove tapered roller bearing 300314 from output shaft Critical Do not to let tooling make contact with bearing surface on output shaft 8 Remove brass Synchro blocker ring 300370 from shift hub assembly 9 Remove two springs 300373 that retain the shift hub 300371 and three synchro dogs 300372 to the rear output shaft 10 Remove tapered roller bearing 300314 from output shaft 20 Shift rail housing sub assembly Tools required 1 4 inch Allen socket 34 inch socket inch socket Procedure 1 Remove 4WD and Low range shift switches 300378 from shift rail housing with 7 8 inch socket Remove three bolts retaining shift rail housing to Atlas case with inch Allen socket Remove shift detent plugs 302019 from shift rail housing with inch socket Remove corresponding detent balls and springs Shift the front shift rail into neutral shift position middle slot Remove rear shift rail from shift rail housing by pulling straight out Remove front shift rail 300381 from shift rail housing by pulling straight out ey s 919 21 VI Cleaning and Inspection Advance Adapters recommends
7. this torque How does this relate to shifting an Atlas When being operated in high traction conditions the Atlas will not shift to its potential especially when shifting out of 4WD If the transfer case becomes stuck in 4WD try driving at least half of the vehicle onto a surface that will allow the tires to slip before re attempting to shift out of 4WD Deactivating locking differentials if applicable will also help in this situation 12 Towing When a vehicle is being towed with the Atlas the shift levers should be in the Neutral position Figure 3 raised towing is the preferred method Transmission towing positions are as follows please also verify in your owner s manual what the vehicle manufacturer recommends Automatic transmissions should be left in park Manual transmissions should be left in any gear 13 III Troubleshooting Noisy Operation Due to the fact that the Atlas is gear driven it will typically create more noise than a typical chain driven transfer case This noise is more noticeable on applications where the direct lever type shifter is used Should your Atlas exhibit a new sound check the oil level and inspect the color of the oil at the sight tube If oil is low or appears to be contaminated change it immediately Gear wine is typically a result of inadequate lubrication This can result if a leak occurs or if water or other substance mixes with the lubrication If noisy condition is not remedi
8. Advance Adapters Atlas 2 Speed Service Manual Advance Adapters 4320 Aerotech Center Way Paso Robles California 93446 USA 800 350 2223 www AdvanceAdapters com gt N VANCE YALA FS SP e z Z 7a E 3177 7 gt G OE Important Notice The descriptions specifications and procedures contained in this service publication are based on the latest product information available at the time of publication approval Advance Adapters reserves the right to discontinue or modify models procedures and specifications at any time without notice Any reference to a brand name in this publication is provided only as an example of the types of tools and materials recommended for use and should not be considered an endorsement Equivalent products may be used Departure from the instructions choice of tools specifications materials and recommended parts mentioned in this publication may jeopardize the personal safety of the service technician or vehicle operator F ADVANCE ADADTCOC and are registered trademarks of Advance Adapter Inc All rights reserved No part of this publication is to be reproduced without prior written permission of Advance Adapters Inc California USA VI VII XI Table of Contents Function and Design Options Identification Power flow diagrams Lubrication Maintenance Operating Instructions Towing Troubleshooting Removal from Vehicle Disassembly Front output Input Rear output Shift r
9. Apply assembly lubrication to rear output yoke seal Apply RTV silicone to inner splines of rear output yoke We no longer use the yoke seal washer on any yokes the silicon on step 16 will seal the yoke to the shaft Do not use P N seal washer 300474 inside of yoke Install rear output yoke Torque retaining nut to 150 lb ft with 1 1 8 inch socket Apply assembly lube to one side of each cluster gear thrust washer 300355 This will help retain the washers in place while installing the cluster gear assembly 55 62 63 64 65 66 Figure 53 Install rear cluster gear thrust washer inside case as shown Figure 54 Install cluster gear shaft 300022 from back side of transfer case aligning flat relief area parallel with bottom of transfer case Push cluster gear shaft through rear case opening until flush with inner surface of rear cluster shaft washer 300355 Install front cluster shaft washer to front inside of case Use special service tool SST 110 to retain washer Install cluster gear needle bearings and spacer as shown in Fig 47 56 Figure 55 67 Position transfer case on work bench as shown Figure 56 68 Hold cluster gear as shown 57 Figure 57 69 Gently lower the cluster gear into the main housing 70 Rotate front rear output yokes back and forth until the cluster gear assembly drops into alignment with SST 110 71 Use SST 110 to retain cluster gear assembly in place 72 Install
10. BEARING 20605 TERED ROLL _IBEARING ATLAS 26885 TAPERED RACE BEARING ATLAS LOW SPEED GEAR SEAL ATLA FRONT REAR OU x YO A ES SHA 34T 005 72 SHIFI DOG ATLAS SYNCHRO ASSEMBLY SYNCHRO ASSEMBLY NG ATLAS 131 SPEEDO WORM Figure 19 exploded view rear output 31 Procedure 1 Start by pressing bearing race 300513 into the tail housing 300104 Ensure that bearing race is fully seated into housing Figure 20 Figure 21 bearing race fully seated 32 2 Install caged needle bearing 300515 into the rear pocket of the output shaft Critical Ensure that the tapered side of bearing faces inside pocket Use special service tool SST 106 Figure 22 3 Slide tapered roller 300313 onto output shaft 33 Checking and setting output shaft endplay The rear output sub assembly utilizes two tapered roller bearings to support the rear output shaft This setup requires shimming to achieve the desired bearing preload during operation While the initial endplay is set at the factory any Atlas rebuild may require an adjustment due to normal bearing wear G nnm Oo r A Figure 16 Figure 17 Temporarily assemble rear output assembly housing shaft bearings shim yoke and nut Fasten output assembly to empty Atlas main housing using existing fasteners as seen in Fig 16 Gently drive the output shaft assemb
11. ED 3 8 16X1 1 4 SHCS RTVSIICONE O O Y jos JSING DIVORCED INPUT 3 8 16X1 1 4SHCS MED STRENGTH THREADLOCK ISING REAR OUTPUT 3 8 16X1 1 4 SHCS USING FRONT OUTPUT 3 8 16X1 1 4 SHCS ISING SHIFT RAIL 3 8 16X1 1 4 SHCS ISING SHIFT RAIL 3 8 16X1 3 4 SHCS JSING SHIFTER SUPPORT 3 8 16X1 1 4 SHCS 3 SING FRONT BRG CAP 5 16 18X1 FHCS 4 RTV SILICONE N BRACKET DIVORCED MOUNT PAN 5 16 18X1 1 4 FHCS BRACKET DIVORCED MOUNT INPUT 3 8 16X1 1 4 SHCS MED STRENGTH THREADLOCK SHAFT CLUSTER 3 8 16X1 2 HHCS 2 Y 2 Rivswicone N jJs2 90 DEGREE 1 8 NPT__ 1 RTVSIICONE N hon PLUG OILPAN S S IBW MAG SEALWASHER Y hon PLUG SHIFT HOUSING SWITCH BORE SHIFT FORK SHIFT RAIL 3 8 24X1 2 CPSS MED STRENGTH THREADLOCK NUT YOKE 26 zna SEAL WASHER one 7 8 20 INT FIT 170in tbs 1 SEAL WASHER TY iso oo 4 Please note that in 2014 Advance Adapters switched most of its bolts for the Atlas to a N D patch fastener The bolts have a locking and sealing property that does not require Loctite or silicone These bolts are reusable for up to 12 times per the manufacture specifications L 4 O 1JJHS SV 11V 11HO9DMA LJOS DEY y 155 V ON OMA 3ZIS JOCINLYVd SHIA LL SZ Ol Jivg oNmvaa Gos 10N oq TWISSLYA AG GdIMOUddVY 1001 AIGWASSVY TVIO4dS NASAVHLIY MONHO FI HLL SddlaVdVv AJONVAGV gnda 3Z3393 ONISNOH AIRS OME WNYSINI LAd
12. GLNO HYAY INN lidzi 8tL 91 S SOHH ldz cX9L 91 S SSdO x91 v7 e 31V1d IWAOWSY 3xHOA IWAOWSY JNOA SVILV 1001 1i 0O01 llv 100 1 WAS JRA AHS 39 JISM 3OVYN 3383dV1 Was IndInO YvWay LNON4 9H8g LNdNI GSONOAIG OYua LNdNI SVI NOldINOS3d AFINIINTI V V SJH NIQOY IN GL S3DV33 S GNNOYD so00 TWWIZd 39YIda NOJ WWWID30 32913 333H1 3 TWWIO30 30 1d OML SSONVASTOL S3HONI NI 3 J SNOISNSWIG GWsASsv IEWASSV C4 LIBIHOded SI ONL SYaldvav JONVAQY 30 NOISSINASd N3LLIYM JHL LNOHLIM JIOHM V SV HO Llavd NI NOILONGOddsy ANY ONI SYaldvVO 3SNVAGQV JO ALaad08 d 310S JHL SI SNIMVYO SIHL NI GANIVINOD NOLLYAWSOANI JHL TWWILNSGIINOD ONY AXVIaIdOudd Figure 60 61 Assembly fluids FLUID APPROVED MANUFACTURERS MEDIUM STRENGTH THREAD stan a7 i IE LOCKING COMPOUND LOCKTITE 271 LAWSON 87137 ANEROBIC SEALANT LOCKTITE 518 RTV SILICONE LAWSON 93204 93844 PERMATEX 81173 ENGINE ASSEMBLY LUBE SYNTHETIC BEARING GREASE ALL W O LITHIUM ASSEMBLY OIL TORCO MFZ SW 90 GEAR OIL Figure 61 LOCATION OF USE INPUT HOUSING BOLTS FRONT DIVORCED MOUNT BOLTS FRONT OUTPUT REAR BEARING RETAINER SHIFTER RAIL HOUSING SIHFTER HOUSING OIL PAN BOLTS TAILHOUSING BOLTS FRONT OUTPUT HOUSING BOLTS YOKE SPLINES CLUSTER GEAR THRUST WASHER INPUT HOUSING SEAL LIGHT COATING APPLIED TO BEARINGS FOR INITIAL STARTUP 62 Recommended hand tools
13. Tools required Dead blow hammer inch socket inch socket inch Allen socket inch socket Procedure sD DO Oe t oP er 10 From the front of the transfer case push the cluster pin out of the case 12 13 14 15 16 17 18 19 20 21 22 23 Start with a clean work area Remove the brass elbow on the top of the transfer case or top of the shifter block Shift the unit into 4WD low range both shift rods back into the case Set the unit upside down on a work surface Remove shifter mechanisms components and divorced bracket if equipped Remove all output yokes Remove oil pan and inspect internal components for signs of unusual wear Remove shift fork to shift rail retaining bolts Remove shift rail housing retaining bolts Remove the cluster pin bolts from both the front and rear of the transfer case Support the cluster gear with one hand as you push out the cluster pin with the other Once the cluster pin is removed remove the cluster gear from the case Be careful so that the caged needle bearings do not fall out of the cluster gear Remove the two thrust washers 300355 from the inside of the case To remove the shift fork assembly use one hand to support the Atlas shift forks from inside the case Using a plastic dead blow hammer gently tap the shift rails from the front of the case Remove six input housing bolts to free the input ring assembly from the transfer case Remove the five bolts
14. ail housing Cleaning and Inspection Assembly Front output Rear output Input divorced shown Shift rail housing Final assembly Front output preload procedure Torque specifications Special service tools SST Page 4 Page 5 Page 7 Page 8 Page 10 Page 11 Page 12 Page 13 Page 14 Page 16 Page 17 Page 18 Page 19 Page 20 Page 21 Page 22 Page 25 Page 26 Page 31 Page 36 Page 39 Page 42 Page 48 Page 60 Page 61 Function and Design The Advance Adapters Atlas transfer case is designed for vehicles that regularly travel over difficult terrain The gear driven transfer case features two speeds and can be ordered in a variety of different configurations Be sure to understand which specific options your Atlas transfer case includes before performing service Some options require different servicing procedures Direct Drive or High Range is always configured as 1 1 ratio When maximum traction is not needed 2WD operation is recommended to prevent wear and tear on non essential front drive components z Transfer Case Options 1 Differential output 2 Low Left driver Right passenger Range Ratio Standard and HD 1 5 1 2 0 1 3 0 1 3 8 1 4 0 1 5 0 1 Shifter Type Single direct lever Dual direct lever Single lever cable shifter Dual lever cable shifter Internal Gears Standard Competition Output Shafts Front 32 spline Rear all 32 spline Left Standard HD Shor
15. as shown Use SST 112 and hammer to set plugs in place Note New freeze plugs are only needed when installing new replacement shift housing Install 4WD shift switch 300378 or plug into hole on front shift rail side of shift housing Tighten to 12 lb ft with inch socket Install Low range shift switch 300378 or plug into hole on rear shift rail side of shift housing Tighten to 12 lb ft with inch socket 41 Final Assembly Tools required Assembly oil spray type SST 100 SST 110 SST 111 Arbor press Torque wrench 34 inch socket 1 1 8 inch socket inch Allen socket Depth micrometer Micrometer LocTite 518 LocTite thread locking compound medium strength RTV silicone Synthetic grease Solvent Clean rags 42 Procedure 1 Install front output tapered race 300512 into hole on rear side of Atlas main case Use SST 100 and arbor press Tapered side should face front Race should be flush with exterior surface of case 2 Apply assembly lubricant to low range gear 309520 as shown Figure 32 3 Install brass synchronizer blocker ring 30370 on low range gear 309520 as shown 43 4 Install Low range bearing 300518 on front output subassembly shaft 300123 as shown Coat bearing with assembly lubrication Figure 34 5 Place Low range gear and synchronizer blocker ring inside Atlas main housing Brass synchronizer side should face front of case 6 Install front subassembly thro
16. ed by oil change disassembly and inspection of individual wear components is recommended Vibration Vibrations can come from several areas in the drive train transmission drivelines axles tires Such vibrations may be most noticeable at the Atlas shifter if equipped with a direct linkage type shift mechanism Be sure to check other components prior to the Atlas In most cases vibration is the result of a worn component such as a CV driveline or failed transmission mount or isolator Improper driveline angles can also result in vibrations Inspect both front and rear driveline angles in relation to the axle pinion yoke Driveline angles greater than 4 degrees can cause a noticeable vibration This type of vibration can be remedied by adjusting axle pinion angle Improper driveline angles are responsible for 99 9 of all noises that seem to be coming from the Atlas If all other components appear to be intact check the Atlas front and rear output shafts for excessive movement Improper yoke nut torque may allow a slight amount of in and out movement Check the yoke nut torque specifications periodically The 32 splined shafts should be torqued at 150 lb ft 14 Difficulty Shifting There are two main reasons an Atlas may be difficult to shift First the linkage could be binding You may need to inspect for possible trouble areas Refer to the Final Installation section under the subtitle Shifter Problem Checklist for more info
17. first o ring 300358 on back side of cluster shaft Figure 58 58 73 74 75 76 80 81 82 83 84 85 86 Push cluster shaft through cluster gear until the second o ring groove is exposed on the opposite side of the main housing Catch SST 110 with free hand Install second o ring 300358 on exposed cluster shaft groove Install both cluster shaft retaining bolts by hand with a inch socket Torque to 12 lb ft Shift each shift fork to the neutral position 77 78 79 Apply assembly lubricant to both shift rail seals 300387 Install one shift rail seal 300387 on each shift rail Use hammer and SST 111 to drive both shift rail seals 300387 into main housing as seen in Fig 51 Figure 59 Clean the oil pan mounting flanges with solvent and a clean rag Install oil pan gasket 301400 and oil pan 301106 Torque 14 oil pan retaining bolts 301401 amp 301402 to 23 lb ft Install oil pan drain plug Torque to 10 foot pounds Install inch site tube fittings into case if case is equipped Torque fittings to 15 lb ft Install site tube if case is equipped Install brass vent fitting on top of case or to the shifter block 59 IX Torque Specifications COMPONENT FASTENER DESCRIPTION a BOLT SEALANT THREADLOCK pra ary HOUSING OIL PAN BLIND 5 16 18X1 FHCS 10 RTVSILICONE O N Ba NG OIL PAN THRU ISING OIL PAN DIVORCED 5 16 18X1 1 4 FHCS USING INPUT MARRIED DIVORC
18. from the front output shaft retainer Remove four rear bearing cap bolts for front output shaft Remove the front subassembly from the case Remove the five bolts retaining the rear output subassembly Remove input sub assembly 17 Front Output Sub assembly Tools required Impact gun Allen wrench socket inch socket Snap ring pliers Press Procedure 1 Remove front output housing 300103 from case 2 Remove rear bearing retainer 300105 from case 3 Remove input gear 309320 from splined section of input shaft 4 Remove caged needle bearings 300517 from shaft 5 Remove brass Synchro blocker ring 300370 from shift hub assembly 6 Remove two springs 300373 that retain the shift hub 300371 and three synchro dogs 300372 to the front output shaft hub 300123 7 Remove tapered roller bearings 300511 from shaft with press 18 Input Sub assembly Tools required Impact gun Allen wrench socket Snap ring pliers 1 1 8 socket Arbor press Procedure 1 Remove six 1 4 inch Allen head bolts 723730 retaining input housing 300106 divorced 300120 std to case 2 Remove input subassembly from case 3 Remove the input gear snap ring 716453 from the input shaft Figure 4 4 Remove input gear 309120 from shaft 300016A 19 Rear output sub assembly Tools required Impact gun Allen wrench socket Snap ring pliers Procedure 1 Remove speedometer housing 300628 from tail
19. ion of the output shaft 12 Install three synchro dogs 300372 with the legs facing the output shaft Figure 23 13 Install two retaining springs 300373 to either side of the hub assembly This retains the three synchro dogs to the synchro hub 35 Input sub assembly divorced housing shown The part number listed in the exploded view are an example of one assembly your application may require different part numbers Tools required Assembly oil spray type SST 100 SST 101 Press Snap ring pliers PART EERST NUMBER DESCRIPTION 300510 IBEARING ATLAS INPUT 6307 _ _ 7 IRETAINING RING ATLAS INPUT GEAR IGEAR ATLAS INPUT 2 0 ISHAFT ATLAS DIVORCED INPUT ORING ATLAS INPUL REAR FRONT OUTPUT BOLT 3 8 10X1 25 SHCS IWASHER 3 78 SHCS HOUSING ATLAS DIVORGED INPUT NUT ATLAS 321 YOKE SFAL ATLAS DIVORCED INPUT SEAL ATLAS 321 SPLINE YOKE ISHIM ATLAS INPUT GEARY 006 010 Figure 24 exploded view divorced input assembly 36 Procedure 1 Start by installing the first of two input shaft main bearings 300510 on the input shaft as shown in Fig 18 Figure 25 2 Once the main bearing is in place on the input shaft place the shaft into the fixture with the flange side of the fixture facing the bearing 3 Use the fixture to hold the input shaft vertically on work surface Install front inpu
20. l Checking oil Check oil level on level ground Drain oil Remove lower plug on oil pan or fitting on lower site tube Refill Install drain plug Fill lubrication through upper site tube on back side of Atlas or through the new fill hole on new units 2014 and newer Race units These units see a complete different type of usage for these applications please refer to instructions AB2000 AB2001 for service recommendations 11 II Operating Instructions Shifting an Atlas Shifting from High range to Low range Verify that the FRONT lever is in NEUTRAL Bring the vehicle to a speed of about 3 5mph and place the transmission into neutral Shift lever into NEUTRAL Place the transmission back into gear and resume driving Shifting from Low range to High range Bring the vehicle up to a speed of 5 20mph and shift the transmission into neutral Shift transfer case shift lever into neutral Apply pressure to lever toward the HIGH position until the Atlas completes the shift into HIGH Put the transmission back into gear and resume driving What to do if the moving vehicle shift was not successful shifting while stationary Manual Transmission Put the transmission into gear with vehicle still stationary and feather the clutch while re attempting the desired shift by holding steady pressure on the shift lever Repeat as needed Automatic Transmission Shift the transmission from drive to reverse while maintaining
21. ly with a soft hammer to seat rear output bearing as seen in Fig 16 Clamp dial indicator base to exterior of Atlas as shown in Fig 17 Use pry bar to apply vertical force to bottom side of flange yoke Record indicator value and compare to factory specification seen below Endplay specification 0 001 0 0025 0 025 0 064mm At 65 80 F 18 27 C To decrease endplay use a smaller shim than the one used for measurement To increase endplay use a larger shim than the one used for measurement Using a micrometer choose an appropriate shim that will adjust endplay into the range given above Disassemble rear output assembly to change to newly selected shim Install new shim onto output shaft and reassemble output shaft assembly Recheck output shaft end play Repeat steps A through L if necessary to achieve correct endplay 34 Rear output continued 4 5 6 7 8 9 Install tail housing 300104 and bearing 300513 onto output shaft Install output yoke and retaining nut Torque to 150 lb ft Install tail housing seal 300473 with special service tool SST 104 With output shaft seal installed remove tail housing from output shaft Install o ring 300490 around tail housing mounting flange base Temporarily remove end play shim 10 Remove bearing 300104 from output shaft Critical do not let tool touch ground needle bearing surface on shaft 11 With the bearing removed install shift synchro hub over the hub sect
22. mb and fore finger to cover up the three synchro dog holes on the shorter side of the shaft 27 6 7 8 Install three synchro dogs 300372 Note Spring retaining flanges should face shaft Figure 13 Install synchro dog synchro spring 300373 on long side of shaft This retains the three synchro dogs to the synchro hub Figure 14 Install second synchro spring into groove on short side of shaft inside void of synchro hub 28 9 Install two needle bearings 300517 on long side of shaft ie P Figure 15 10 Install brass blocker synchro ring 300370 on shaft Ensure three notches line up with the synchro dogs in the hub Figure 16 29 11 Apply assembly lube to needle bearings and synchro ring 12 Install front output high range gear as shown Figure 17 13 Install thrust washer 300393 on shaft Ensure that chamfered edge is pointed towards gear 14 Install tapered roller bearing 300513 with minor end facing up Figure 18 30 Rear output sub assembly The part number listed in the exploded view are an example of one assembly your application may require different part numbers Tools required Assembly oil spray type SST 104 SST 105 SST 106 Press Snap ring pliers Dead blow hammer Dial indicator Micrometer Pry bar Allen wrench socket ESG THOUS IG ATAS SI ANDARD gt S H EARN 00491 J gt RIM AIL 300573 IBEARING 00514
23. o not tighten with impact gun 22 Apply assembly lubricant to Low range gear 309520 as shown in Fig 23 23 Install brass blocker synchro ring 300370 on low range gear 309520 24 Place low range gear and blocker synchro ring inside Atlas main housing input side Brass synchronizer side should face front of case 50 25 26 27 28 dat l K Figure 46 low range gear installed in preparation for rear output sub assembly Align low range gear 309520 with one hand while installing rear output sub assembly in place with other hand Critical Align brass blocker synchro ring 300370 with the three synchro dogs 300372 in the input shaft hub Position case on workbench with front side facing up Insert rear output shaft through input bore and then into previously installed low range gear Install large tapered roller 300511 onto output shaft 51 Figure 47 tapered roller installed on shaft while in main case 29 Reposition case upside down on workbench Hold output shaft tight against rear portion of case while rotating case into position 30 Use snap ring pliers to install snap ring 300627 on output shaft as shown 31 Install soeedometer gear 300625 on output shaft i a Uus SS s a DS V ES awwN ws q ar 2 i satis z iad 7 rr A A AR ee i Fa Figure 48 speedometer gear installation with shaft in main housing 32 Install rear output shim 300491 on out
24. olvent to clean mating surfaces of shift housing sub assembly and main case where sub assembly is to be installed 46 Apply silicon to mounting face of shift rail housing subassembly Figure 51 47 Position transfer case on workbench with tail housing facing you 48 Install shift forks 301378A amp 301378B on appropriate shift hub Critical Install the shift forks with minor side of tubular fork interface towards the rear of case longer curved surface of fork should point down towards work surface 54 49 50 51 52 53 54 55 56 57 58 59 60 61 Figure 52 Insert shift rail housing sub assembly into main housing Align shift fork holes with corresponding shift rail Wiggle the shift sub assembly as you attempt installation Install three shift rail housing support bolts by hand Torque to 30 lb ft with inch Allen socket Position transfer case upside down on workbench so that the input shaft faces you Attach shift rail rod ends 303055 to threaded ends of shift rails Place both shift rails in the Neutral position Align each shift fork so that the retaining screws 300385 can be installed in each shift rail Apply medium strength LocTite to the two 3 8 inch mounting screws 300385 Secure each shift fork to corresponding shift rail by hand with appropriate tool Torque to 150 lb in Test each shift fork to ensure bind free operation After testing place both shifters in low range
25. pressure on the transfer case shifter lever DO NOT SHIFT THE TRANSMISSION INTO PARK If unsuccessful turn off the engine with the transmission still in neutral Now shift the transfer case into gear and re start the engine General notes on Shifting The Atlas Transfer Case is a Synchronized gear box This means that in order for the case to shift easily and smoothly the vehicle must be moving in a forward direction This will allow the synchronizers to function properly Note that when the transfer case is shifted when not in motion the teeth may or may not be aligned If the teeth are aligned then the unit will slip into gear easily If the unit does not slip into gear easily then no amount of pulling on the lever will cause the unit to shift under these circumstances Once the transfer case is allowed to rotate slightly or the binding is relieved it should slip right into gear The Atlas is classified as a Part Time Transfer case As with all part time transfer cases 4WD should be used in low traction conditions only Anytime the unit is in 4WD low or 4WD high the rear output and the front output are locked to each other and can only spin at the exact same speed This characteristic is essential for extreme off road usage but becomes a hindrance on dry pavement When a vehicle turns a corner the front driveshaft spins at a different speed than the rear driveshaft This creates a binding in the drive train if the tires cannot slip to relieve
26. put shaft 52 33 34 35 36 37 38 39 40 Figure 49 Install rear output housing onto rear output shaft aligning the five mounting bolt holes with the tapped holes in the Atlas main housing Coat each of five 5 16 inch Allen bolts 301401 with RTV Silicone as shown new bolts 2014 do not require Tighten the five rear output housing bolts by hand with 5 16 inch Allen socket Torque to 35 lb ft Apply assembly lubrication to rear output bearing 300511 and pocket bearing 300515 Apply assembly lubrication to synchronizer cone on input shaft subassembly Install brass synchro blocker on rear output gear hub Align the three notches of the brass synchronizer blocker ring with the synchronizer dogs in the rear output sub assembly Install input sub assembly Correct housing alignment is seen when the indicating mark is oriented towards the bottom of the main housing Note allignment hole location Figure 50 53 41 Support the splined section of the rear output shaft as you mate the input sub assembly with the rear output sub assembly Be sure that the synchronizer dogs line up properly as the two sub assemblies are joined 42 Align the six mounting holes of the input housing with threaded holes in the case 43 Apply medium strength LocTite to the six 5 16 inch Allen bolts 301401 44 Install the six mounting bolts and washers by hand to ensure proper thread engagement Torque to 40 lb ft 45 Use s
27. rmation Notes on shifting Shifting the Atlas is an acquired touch and feel You will not learn it overnight It is twice as hard to shift the transfer case if the vehicle is not at least slowly rolling forward In addition trying to shift the transfer case while the steering wheels are turned puts a bind on the synchronizers making it almost impossible to shift in or out of gear 15 IV Removal from Vehicle Recommended Equipment Floor jack to support the transmission when the crossmember is removed Transmission jack for raising and lowering the transfer case Pneumatic impact gun Magnetic parts tray Procedure OO NAMA Q N Prior to removing the Atlas from a vehicle place shifter s in neutral and drain the lubrication fluid Disconnect vehicle negative battery cable Remove front and rear drivelines from vehicle Disconnect shift linkage by removing e clips that retain shift rod button ends Remove divorced Atlas mounting bracket from chassis Support the rear portion of the Atlas with a transmission jack or similar device Remove six mounting bolts that secure the transfer case to the transmission Disconnect the speedometer cable or wires Remove any wiring related to the 4WD 4L switches 10 Remove the vent hose from the transfer case 11 Separate the transfer case from the transmission by pulling straight back 12 After separation lower transfer case from vehicle 16 V Disassembly
28. t Clocking Options DEPENDING ON TRANSMISSION TAILHOUSING BOLT PATTERN 0 3 7 10 14 17 20 21 24 28 31 and 38 degrees Right 4 11 14 18 21 25 28 and 35 degrees 7 Yoke Options e CV Constant Velocity e Non CV 32 Spline e 1310 e 1310CV e 1330CV e 1350 e 1350CV e 1410 e 1410U e 1300 flange e 1410 flange e Toyota flange 8 Soeedometer e Mechanical 13T worm with variety of pinion gear counts available e Electronic GM VSS and custom _ 9 Input Configuration e Divorced e 10 spline e 21 spline e 23 spline long amp short e 25 spline e 26 spline 2012 amp newer JK e 27 spline e 28 spline e 29 spline also offered in a H D e 31 spline e 32 spline also offered in a H D e 35 spline e 34 spline Transfer Case Identification All Atlas transfer cases come with an identification number that correlates to a customer order number This number can be found on the back of the housing below the cluster pin Figure 1 Advance Adapters recommends you copy your unit s unique serial number in the space provided below This will come in handy should you ever need to reference it for theft recovery replacement parts or future upgrades AtlasID _ Power Flow Diagrams 2WD HI HCG 1 Wh fp Neutral N M Taa a oe Z _ MM TZ O 1 4WD Hi AY TT TY s NT ANI NWON lt 777 ICU SMNS 4WD Low aN we Ue wass 77 46 Lubrication
29. t housing 300106 divorced 300102 std 5 Install second input shaft bearing 300510 on input shaft 6 Press both bearings into input housing with press Use special service tool SST 101 on 7 top and SST 100 on the bottom Figure 26 37 8 Press seal 300503 into input housing using SST 101 Figure 27 9 With both bearings and seal in place install input gear onto splined section of input Shaft 10 Use snap ring 716453 to retain input gear to input shaft Figure 28 38 Shift rail housing sub assembly The part number listed in the exploded view are an example of one assembly your application may require different part numbers Tools required Assembly oil spray type SST 112 Arbor press Flat head screwdriver or similar Torque wrench inch socket inch socket ITEM NO PART NUMBER lt S AF LA 4 SHAFT ATAS REAR SHIFT fr OD AS SHIF JE OC PLUG S 5 SHIFT SETENT SPRING ATLAS SHIFT DETENT SHIFT D o Z S j SHIFT DETENT 378 TEXT 25 SHCS CRIPTION I HOUSING ATI CAS SHIFT RAL ASSEMBLY CAIL ICCA op OLES ONN CS CA SE REAR R RH CA SE FRONT CASE FR ONT RH CASE REAR Ui Oa e T gt IWANAAIDINIGDIOC a h d i wit I Bie IC CCC CaCO CO O 00 CO O CININACO O CO JA tepa 3 Dj amdi hi amd OOS WIN Co Co ax Oly CACO NOIR BS RO 3 SIR OIRS MARINARA a
30. the following practices for powertrain assembly Part cleanliness Thoroughly clean all parts prior to assembly e Less debris contamination in oil e More accurate part fitment e Maximizes oil seal life e Reduces bearing wear Figure 5 shows correctly cleaned housing on left and dirty housing on right Part inspection Inspect used and new parts for signs of damage or wear prior to assembly e Allows for easier assembly e Guarantees a good repair e Damaged used parts may indicate other problems 22 Figure 6 damaged component Magnetic drain plug inspection Inspect debris collected by magnet Easy to check when performing oil change A small amount of material is normal due to wear Larger amounts of debris may indicate a problem Figure 7 normal amount of debris 23 Figure 8 excessive debris indicates problem Bearing installation e Leave bearing in original packaging until just before installation reduces risk of debris in bearing e Bearing into housing press on outer race e Bearing onto shaft press on inner race Inner Race Outer Race Figure 9 24 Vil Assembly The Atlas II transfer case consists of six subassemblies Each subassembly requires a specific set of procedures In the following pages you will find step by step instructions for each subassembly Six main sub assemblies In order of assembly e Front output e Rear output e Input e Shift rail housing e Cluster gear
31. ugh front output opening of Atlas main housing case Hold low range gear up with opposite hand as shown Figure 35 7 Carefully align brass blocker synchro ring 300370 with the three synchro dogs 300372 in the front output shaft hub 8 Install front output washer 300509 onto front output shaft with chamfered edge facing towards gear 44 9 Install tapered roller 300511 on front output shaft as shown Coat bearing with assembly lubrication Figure 36 10 Align rear side of front output shaft with finger while pushing front subassembly in place with other hand 11 Reposition case on workbench as shown n Figure 37 45 12 Install o ring 300490 on front output housing as shown Figure 38 13 Install front output housing ensuring that holes line up with threaded holes in Atlas main housing Figure 39 14 Coat each of the five retaining bolts with RTV silicone prior to installation Torque bolts to 35 foot pounds with inch Allen socket new bolts 2014 have a seal patch sealant on them and do not use silicon Figure 40 15 Apply assembly lubrication to front output yoke seal 46 16 17 18 19 Apply RTV silicone to inner splines of front output yoke We no longer use the yoke seal washer on any yokes the silicon on step 16 will seal the yoke to the shaft Do not use P N seal washer 300474 inside of yoke Install front output yoke Torque retaining nut to 150 Lb ft with 1 1 8

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