﻿GET_GEVOMechL2_08_01_01_91 - ANIMATION Screen
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Gear Case Assembly

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1. Position the nose of the traction motor down on wooden blocks.

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2. Using the Guide Pin Kit (Part Number 41B539007G2), install the motor-side axle seal (gutter) on the axle with the lip of the seal located over the flinger.

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3. Apply a 0.125 to 0.25-inch (3.18 to 6.4-mm) bead of DOW 832 sealant in the groove and latch the seal.

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4. Apply a 0.125-inch (3.18-mm) bead of sealant to the latch joint.

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5. Install the wheel-side axle seal (gutter) to the axle assembly with the lip of the seal located over the wheel and gear hubs.

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6. Apply a 0.125 to 0.25-inch (3.18 to 6.4-mm) bead of sealant in the groove and latch the seal.

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7. Apply a 0.125-inch (3.18-mm) bead of sealant to the latch joint, then remove excess sealant.

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8. Prior to installing the bottom gear case half, apply 0.25-inch (6.4-mm) bead of sealant to the groove of the pinion bore seal, continuously around the entire circumference of the seal.

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9. Install the bottom half of the gear case, then verify engagement of the gear case leg with the groove in the pinion bore seal, and the motor-side and wheel-side gutters with the gear case opening.

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10. Use C-clamps to draw the bottom half of the gear case to within 0.50 inches (12.7 mm) of the U-tube and motor lugs.

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11. Remove the adhesive backing from the Gortex tape (Part Number 41E903878P32) and apply the tape to the center bolt pad between the axle bore and pinion bore on the upper gear case half.

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12. On the top gear case half, apply a 0.125-inch (3.18-mm) bead of sealant along the entire split line surface, just inside the bolt holes.

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13. Install the top half of the gear case, then verify engagement of the gear case leg with the groove in the motor pinion end bore seal, and the motor-side and wheel-side axle seals (gutters) with the gear case opening.

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14. Use C-clamps on the split line flanges at the gear case ends to draw the halves together evenly, then position C-clamps near the gear case center line to prevent misalignment.

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15. Fasten the gear case halves as follows:

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a. Install one split line bolt and washer at the axle end, then draw the gear case halves together but do not tighten.

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b. Install and hand-tighten a second bolt and washer on the motor side axle end.

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c. Install and hand-tighten a third bolt and washer between the axle and pinion bores.

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d. Install and hand-tighten a fourth bolt and washer between the axle and pinion bores.

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e. Install the remaining bolts and washers that hold the gear case halves together, and tighten all bolts evenly.

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f. Torque all bolts to the proper value.

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g. Verify closure of the upper gear case half by \"shim checking\" with a 0.010-inch (0.254-mm) shim in the wheel-side flange at the pinion end.

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16. Remove the guide pins and install the mounting bolts (one at a time), then hand-tighten the bolts.

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17. Torque the gear case-to-motor and gear case-to-U-tube bolts to the proper value, then, to seal out moisture, apply DOW 832 sealant to the open end of the threaded through holes for the gear case mounting bolts, completely filling the end of the bolt holes.

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18. Attach a lifting strap to each axle journal bearing, then lift the traction motor, axle, and wheels assembly and rotate 90° to return the traction motor combo to the horizontal position.

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19. On gear cases with solid-fill plugs, add lubricant to the gear case as follows:

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a. Remove the fill plug.

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b. Fill the gear case with 14.5 quarts (13.7 liters) of lubricant.

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c. Using a clean rag, wipe the magnet on the fill plug.

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d. Apply Hylomar Thread Sealant to the fill plug threads and torque to the proper value.

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e. Apply a safety lock wire to the fill plug and the drain plug.

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20. On gear cases with spring-loaded fill plugs, add lubricant to the gear case as follows:

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a. Pull on the plug cover and hold the fill plug open to add lubricant.

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b. Fill the gear case with 14.5 quarts (13.7 liters) of lubricant.

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c. Release the plug and allow the spring loading to close the fill plug.

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21. Assemble the breather to the top of the gear case.
