Transfer Case: Reassembly
- Press fit needle bearing into center case to within .12" (3.0 mm) of case bottom. Seat oil seal flush with case surface and lubricate seal. Install oil gutter and oil guide. Install needle bearing to within .12" (3.0 mm) of case bottom. Install oil seal on rear case flush with case surface. If rear case cover was removed, install.
- Press bearing onto front output shaft. Drive front output shaft into center case. Install bearing onto rear output shaft and install snap ring. Install needle bearing, low output gear and reduction clutch hub onto rear shaft and secure with snap ring.
- Install assembled rear output shaft and bushing into center case. Assemble shift forks. See Fig 1. Install clutch sleeve with straight spline facing groove mark forward. Alignment marks of hub and sleeve should face rearward.
- Install front drive shaft fork assembly, sleeve and hub together into center case. Install locating ball and spring into case and install bolt loosely. Install sprocket and chain onto rear output shaft. Install needle bearing, steel ball and bushing on to sprocket. Install steel ball on rear output shaft. See Figure and Figure .
- Press second bearing onto rear output shaft and place support base at lower end of shaft pressing on bearing. Install large snap ring and speedometer drive gear and secure it with a smaller snap ring. Install reduction clutch hub and sleeve. Ensure sleeve has tapered splines.
- Install sleeve and hub on reduction shift shaft. Install locating ball and spring into case and leave bolt loose. Apply sealant to rubber plug and install securely.NOTE: When installing reduction shift shaft, front drive shift shaft must be placed in 4WD.
- Install steel ball, thrust washer, needle bearing, spacer and needle bearing on countershaft. Install countershaft into case with new "O" ring. Install countergear, steel ball, thrust washer and low gear needle bearing. Assemble bearing with snap rings. Install oil seal into front case, with edge flush with case.
- Install drive input gear assembly into front case and install snap ring. Lubricate all internal assemblies prior to bolting cases together. Ensure input gear meshes with countergear. Tighten front case bolts to 17 ft. lbs. (23 N.m). After torquing bolts, turn input gear and rear output shaft by hand to ensure smooth operation.
- Measure rear case dimension "A" (from mating surface to bottom of bearing bore) using a straightedge and a depth gauge. See Fig 2 and Fig 3. Place straight edge on bearing and measure bearing height "D" (from center case mating surface to bearing top). DO NOT bridge straightedge between bearing and output front shaft bearing to prevent false measurements. See Fig 2 and Fig 3.
- Use formula C = A + B - C + D to select correct shim to install in bearing bore or rear case. See CLEARANCE "C" SHIM table.CLEARANCE "C" SHIM
Clearance "C" - In. (mm) Shim Size - In. (mm) 0-.005 (0-.13) None .005-.009 (.13-.23) .004 (.10) .009-.013 (.23-.33) .008 (.20) .013-.017 (.33-.43) .012 (.30) .017-.021 (.43-.53) .016 (.40) .021-.023 (.53-.58) .020 (.50) - Install steel ball and the 4WD switch. Tighten switch to 14 ft. lbs. (19 N.m). Install the 4WD switch lead clamp. Lubricate select return system assembly and install to case. See Fig 4 Tighten select return spring bolt to 22 ft. lbs. (35 N.m). Apply sealant to gear shift lever case and tighten bolts to 17 ft. lbs. (23 N.m). Apply sealant to the rear case and install. Tighten rear case bolts to 17 ft. lbs. (23 N.m).
- Install gear shift control lever temporarily and ensure smooth operation in each gear selection and shaft for rotation. Confirm 4WD comes on in 4WD positions 4H and 4L. Remove shift lever once smooth operation of all functions is ensured.