SERVICE BULLETIN

Ref No.: 2005/1015

LARGE TRUCK TRANSFER CASE IDL FORK

UPGRADE - AMENDED, NOVEMBER 2005
Machine VIN PIN Part Manuals Affected

B35D NA NA 872068
B40D NA NA 872068
B40D 6x4 NA NA 872096
350D NA NA
400D NA NA
AH350 NA NA 872068
AH400 NA NA 872068
AH500 NA NA 872107
B50D AEB4128503R001296 NA 872107
INTERCHANGEABILITY (ICA)
YES = New and Old parts are interchangeable NO = New and Old parts are not interchangeable → = New part can be used instead of Old part but not vice versa
NEW PART DESCRIPTION ICA OLD PART NO. DESCRIPTION
NO.
226590 ASSY,FORK WITH BUTTONS → 225248 FORK,

A design change of the large truck (35 to 50 ton) transfer case inter axle differential lock fork was introduced. The change entails
brass ‘buttons’ added onto the fork contact surface area, where it makes contact with the sliding part of the dog clutch - refer fig. 1.
This to reduce wear in this area, in the situation when the IDL teeth are not yet meshed.

Fig. 1 - 226590
In the 35/40 ton ADT’s and B50D/AH500D transfer cases, all transfer cases with serial number prior to 1421 and 052, respectively,
will still have the old type fork, p/n 225248.

AFFECTS VALIDITY YES NO Implementation Date: 21/02/2005 OPERATION CIRCULATION YES NO

Warranty: 8 Hitachi: 9
On repair/as requested: 9 John Deere: 9
Special equipment required: 8 Bell Customers: 8
P/No change/addition/supersession: 9 Bell Dealers: 9
Use up stock on hand: 8 Parts Team: 9
Scrap stock on hand: 8 Sales Team: 8
Return stock for credit: 9 Service Team: 9
Mod into Production: 9
Lubrication affected: 8 REASON FOR BULLETIN YES NO
Safety: 8 Improvement: 9
Urgency: 8 Reactionary: 9

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 SERVICE BULLETIN
Ref No.: 2005/1015

PROCEDURE TO REPLACE FORK - 35 & 40 ton ADT TRANSFER CASE

Removal of original fork
1. Remove the rectangular clutch cover on top of the clutch housing, retained by 8 off M6 bolts. Ensure that this area is free of
debris before removal of the cover.
2. Remove the round IDL piston cover, on the clutch housing
3. Loosen the M7 cap screw, on the fork.
4. Unscrew the piston until it can be pulled out of the clutch housing, allowing the removal of the fork.

Installation of new fork - 226590

1. Install the M7 cap screw into the fork.
2. Position the fork in the clutch housing, ensuring that the fork fits easily into the groove of the clutch slide.
IMPORTANT : The clutch slide must be free to move on the shaft spline length, meshing completely with the dog
clutch teeth of the carrier. If this is not possible, articulate the truck, as this would cause relative rotation between
front and rear output shafts of the transfer case - lining up the IDL teeth for proper meshing.
3. Apply a thin layer of lithium based grease to piston bore of clutch housing. Slightly lubricate the support journal for piston at
clutch housing with grease. Do not contaminate M18 X 1,5 threads.
4. Fit the spring and piston in the clutch housing. Screw the piston into the fork, and tighten the M7 cap screw until all thread
clearance between fork and piston has been taken up, but free rotation is still possible.
5. Apply a thin layer of lithium based grease to lip of seal and fit to the piston.
Note: Seal lip of seal facing away from body of piston.
6. Fit piston cover with O-ring and tighten bolts to 54 Nm.
7. Apply air pressure (6.5-8 bar max) to engage clutch.
Note: Thread at air connection is M12 x 1.5.
8. Ensure that teeth of clutch slide and carrier are fully engaged.
IMPORTANT : When setting the IDL gap, the dog clutch slide teeth flanks MUST NOT make contact with the teeth
flanks of the carrier. If there is contact the fork setting can not be done, as free movement of the slide is absolutely
necessary for the adjustment.
9. The minimum clearance between the teeth of the carrier and the valley of the slide teeth is 0,1 mm (0.004 in), and should not
exceed 0.15 mm (0.006 in) - refer fig. 2 for measurement location.
Note : A bigger gap will be measured between the teeth of the slide and the valley of the carrier teeth due to separation ridges
which are on the teeth of the carrier clutch section - refer fig. 3

Fig. 2 - Adjustment area Fig. 3 - Separation ridges

10. The clearance is adjusted by rotating the piston. Use flat spanner 13 mm (1/2”) A/F.
11. When the clearance have been set the clutch must be disengaged to check that there is a clearance of 1,1 mm minimum
between tips of dog teeth.

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 SERVICE BULLETIN
Ref No.: 2005/1015

12. After adjustment has been completed remove the M7 cap screw. Apply Loctite 243 to the thread. Re-install the cap screw and
torque to 30 Nm. Ensure that the piston does not rotate when tightening the cap screw.
13. Apply Loctite 518 to the sealing area, of the rectangular clutch cover, at the clutch housing. Fit the M6 screws and torque to 12
Nm.

PROCEDURE TO REPLACE FORK - B50D & AH500D TRANSFER CASE

Removal of original fork
1. Remove the rectangular clutch cover on top of the clutch housing, retained by 8 off M6 bolts. Ensure that this area is free of
debris before removal of the cover.
2. Remove the IDL protection cover, disconnect the IDL switch and remove the round cover (piston guide) which retain the spring
and piston assembly.
3. Loosen the M7 cap screw, on the fork.
4. Unscrew the piston until it can be pulled out of the clutch housing, allowing the removal of the fork.

Installation of new fork - 226590

1. Install the M7 cap screw into the fork.
2. Position the fork in the clutch housing, ensuring that the fork fits easily into the groove of the clutch slide.
IMPORTANT : The clutch slide must be free to move on the shaft splines, meshing completely with the dog clutch
teeth of the carrier. If this is not possible, articulate the truck, as this would cause relative rotation between front and
rear output shafts of the transfer case - lining up the IDL teeth for proper meshing.
3. Apply a thin layer of lithium based grease to piston bore of clutch housing. Slightly lubricate the support journal for piston at
clutch housing with grease. Do not contaminate M18 X 1,5 threads.
4. Ensure that the small seal, in the clutch housing piston bore, is still in position, and that it hasn’t been dislodged during removal
of the piston.
5. Screw the piston into the fork, and tighten the M7 cap screw until all thread clearance between fork and piston has been taken
up, but free rotation is still possible.
6. Insert the spring into the clutch housing.
7. Apply a thin layer of lithium based grease to bore of piston guide and fit to clutch housing. Fit piston guide with screws and
tighten to 25 Nm.
8. Ensure that teeth of clutch slide and carrier are fully engaged.
IMPORTANT : When the setting the IDL gap, the dog clutch slide teeth flanks MUST NOT make contact with the teeth
flanks of the carrier. If there is contact the fork setting can not be done, as free movement of the slide is absolutely
necessary for this operation.
9. The minimum clearance between the teeth of the carrier and the valley of the slide teeth is 0,1 mm (0.004 in), and should not
exceed 0.15 mm (0.006 in) - refer fig. 2 for measurement location.
Note : A bigger gap will be measured between the teeth of the slide and the valley of the carrier teeth due to separation ridges
which are on the teeth of the carrier clutch section - refer fig. 3
10. The clearance is adjusted by rotating the piston. Use flat spanner 13 mm (1/2”) A/F.
11. When the clearance have been set the clutch must be disengaged to check that there is a clearance of 1,1 mm minimum
between tips of dog teeth. Disengaging the clutch must be done by connecting an air hose, from the workshop, (pressure
between 6.5 and 8 bar) to the M12x1.5 pressure port on the clutch housing.
12. After adjustment has been completed remove the M7 cap screw. Apply Loctite 243 to the thread. Re-install the cap screw and
torque to 30 Nm. Ensure that the piston does not rotate when tightening the cap screw.
13. Apply Loctite 518 to the sealing area, of the rectangular clutch cover, at the clutch housing. Fit the M6 screws and torque to 12
Nm.
14. Re-connect the IDL harness to the switch, fit the IDL switch protection shield with the cap screws to piston guide and torque to
25 Nm.

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 SERVICE BULLETIN
Ref No.: 2005/1015

Fig 4: New parts - 35 and 40 ton ADT transfer case

I Vin Series
QT
TE PART No. DESCRIPTION From: REMARKS
Y
M To:
3 226590 1 ASSY,FORK WITH BUTTONS From drop box serial number 1421 onwards
5 226591 4 BUTTON,FOR 226590 FORK From drop box serial number 1421 onwards
6 226592 2 PIN,SPRING DIA 3 X 6 From drop box serial number 1421 onwards

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 SERVICE BULLETIN
Ref No.: 2005/1015

Fig 5: New parts - 50 ton ADT transfer case

I Vin Series
QT
TE PART No. DESCRIPTION From: REMARKS
Y
M To:
3 226590 1 ASSY,FORK WITH BUTTONS From drop box serial number 052 onwards
5 226591 4 BUTTON,FOR 226590 FORK From drop box serial number 052 onwards
6 226592 2 PIN,SPRING DIA 3 X 6 From drop box serial number 052 onwards

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