Lull 944E-42 Service Manual User Manual download pdf (Page 200)

100

101

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.

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