TM 5-3895-374-24-2 REPLACEMENT OF PARTS A  DODGE  TORQUE-ARM  Speed  Reducer  can  be  dis- assembled  and  reassembled  by  careful  attention  to  the instructions   following,   using   tools   normally   found   in   a maintenance department. Cleanliness is very important to prevent the introduction of dirt  into  the  bearings  and  other  parts  of  the  reducer.    A tank  of  clean  solvent,  an  arbor  press,  and  equipment  for heating    bearings    and    gears    should    be    available    for shrinking these parts on shafts. Our  factory  is  prepared  to  repair  reducers  for  customers who  do  not  have  proper  facilities  or  who  for  any  reason desire factory service. The oil seals are of the rubbing type and considerable care should   be   used   during   disassembly   and   reassembly   to avoid damage to the surface on which the seals rub. The keyseat  in  the  input  shaft  as  well  as  any  sharp  edges  on the   output   hub   should   be   covered   with   tape   or   paper before   disassembly   or   reassembly.      Also   be   careful   to remove any burrs or nicks on surfaces of the input shaft or output hub before disassembly or reassembly. ORDERING PARTS: When   ordering   parts   for   reducer,   specify   reducer   size number,  reducer  serial  number,  part  name,  part  number and quantity. It  is  strongly  recommended  that  when  a  pinion  or  gear  is replaced, the mating gear or pinion be replaced also. If the large gear on the output hub must be replaced, it is recommended  that  an  output  hub  assembly  with  a  gear assembled  on  the  hub  be  ordered  to  secure  undamaged surfaces   on   the   output   hub   where   the   oil   seals   rub. However,  if  it  is  desired  to  use  the  old  output  hub,  press the gear and bearing off and examine the rubbing surface under the oil seal carefully for possible scratching or other damage resulting from the pressing operation.  To prevent oil leakage at the shaft oil seals the smooth surface of the output hub must not be damaged. If  any  parts  must  be  pressed  from  a  shaft  or  from  the output  hub,  this  should  be  done  before  ordering  parts  to make  sure  that  none  of  the  bearings  or  other  parts  are damaged in removal.   Do  not  press  against  outer  race  of any bearing. Because     old     shaft     oil     seals     may     be     damaged     in disassembly it is advisable to order replacements for these parts. If replacing a bearing or a shaft, it is advisable to order a set   of   shims   for   adjustment   of   bearings   on   the   shaft assembly. If  replacing  a  housing,  a  set  of  shims  should  be  ordered for  each  shaft  assembly  because  the  adjustment  of  the bearings on each shaft assembly is affected. REMOVING REDUCER FROM SHAFT: WARNING To ensure that drive is not unexpectedly started,  turn oft and lock out or tag power source before proceeding.    Failure  to  observe  these precautions     could     result     in     bodily injury. WARNING External    loads    may    cause    machine movement.        Block    machine    before removing  any  drive  train  components. Failure   to   observe   these   precautions could result in bodily injury. STRAIGHT BORE Loosen  screws  in  both  output  hub  collars.    Remove  the collar next to end of shaft.  This exposes three puller holes in  output  hub  to  permit  use  of  wheel  puller.    In  removing reducer from shaft be careful not to damage ends of hub. TAPER BUSHED 1.   Remove bushing screws. 2.   Place the screws in the threaded holes provided in the bushing  flanges.    Tighten  the  screws  alternately  and evenly  until  the  bushings  are  free  on  the  shaft.    For ease  of  tightening  screws  make   sure   screw   threads and threaded holes in bushing flanges are clean. 3.   Remove the outside bushing, the reducer and then the inboard bushing. DISASSEMBLY: 1.   Remove   all   bolts   from   housing.      Drive   back   hollow dowel pins on either side of housing.  Remove back-up plates   and   snap   rings   on   the   output   hub   on   taper- bushed   reducers.      Open   housing   evenly   to   prevent damage to parts inside. 2.   Lift shaft, gear and bearing assemblies from housing. 3.   Remove   seals,   seal   carriers   and   bearing   cups   from housing. REASSEMBLY: 1.   Output Hub Assembly: Heat gear to 3250 to 350°F for shrinking onto output hub.  Heat bearing cones to 250° to 270°F for shrinking onto output hub. 2.  Countershaft  Assembly:  Heat  gear  to  325°  to  350°F and bearing cones to 250° to 270°F for shrinking onto shaft. 3.  Input  Shaft  Assembly:  Shaft  and  pinion  are  integral. Heat bearing cones to 2500 to 270°F for shrinking onto shaft. 4.  Drive the dowel pins back into position in the right-hand housing half. 5.  Install  countershaft  cover  in  right-hand  housing  half. Place housing half on blocks to allow for protruding end of   output   hub.      Install   bearing   cups   in   right-hand housing half making sure they are properly seated. 6.  Mesh  output  hub  gear  and   small   countershaft   gear together  and  set  in  place  in  housing.    Set  input  shaft assembly in place in the housing.    Make  sure  bearing rollers  (cones)  are  properly  seated  in  their  cups.    Set bearing cups for left-hand housing half in place on their rollers. (page 3 - 1284)