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Transfer Case Reassembly

  1. Install appropriate bearing races in transfer case (as needed). Use original washers. Install driven pinion in transfer case. Install NEW spacer and rear bearing inner race to driven pinion. Install lock nut and tighten to 218 ft. lbs. (295 N.m).
    2. NOTE: If tightening torque for driven pinion lock nut is greater than specification and starting torque is less than specification, loosen lock nut and lubricate nut threads. Tighten lock nut and recheck starting torque.
  2. Check starting torque of driven pinion using Driven Pinion Nut Socket (09326-20011). See Figure. Starting torque should be 7.8-11.2 INCH lbs. (.9-1.3 N.m) for used bearings, and 8.7-13.0 INCH lbs. (1.0-1.5 N.m) for new bearings. If starting torque is less than specification, tighten lock nut 5-10 degrees and recheck. If starting torque is greater than specification, replace spacer.
  3. Heat ring gear in boiling water for 10 minutes. Once water has evaporated, place ring gear in original location on center differential control coupling. Tighten bolts in crisscross pattern to specification. See TORQUE SPECIFICATIONS .
  4. Install center differential control coupling in transfer case. Install original washer and bearing race in bearing retainer. See Figure. Install original washer. Install bearing retainer. Tighten bolts in crisscross pattern to specification.
  5. Check ring gear backlash. See Figure. Backlash should be .004-.006" (.10-.15 mm). If backlash is not within specification, replace washer on ring gear side of transfer case. Washer thicknesses available are .082" (2.07 mm) to .118" (3.00 mm) in .001" (.03 mm) increments.
  6. Coat ring gear teeth with appropriate marking compound. Rotate gear until clear contact pattern is obtained. Check pattern for proper contact. See GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. If proper contact pattern is not present, replace washer behind driven pinion front bearing inner race. Washer thicknesses available are .047" (1.20 mm) to .065" (1.65 mm) in .0004" (.01 mm) increments.
  7. After proper ring gear tooth contact pattern is achieved, check driven pinion total rotating torque. Driven pinion total rotating torque should be an increase of 1.7-2.6 INCH lbs. (.2-.3 N.m) over starting torque for new bearings or an increase of .9-2.6 INCH lbs. (.1-.3 N.m) over starting torque for used bearings. If total rotating torque is not within specification, change washer in bearing retainer. Washer thicknesses available are .058" (1.47 mm) to .102" (2.58 mm) in .001" (.03 mm) increments.
  8. Remove bearing retainer from transfer case. Remove bearing race and washer from bearing retainer. Install side gear shaft holder bearing in bearing retainer. Install snap ring and oil seal. Install washer and bearing race. Install "O" rings on bearing retainer. Install bearing retainer. Tighten bolts in crisscross pattern to specification. See TORQUE SPECIFICATIONS .
  9. Recheck driven pinion total rotating torque. Install remaining oil seals. Install "O" ring in center differential lock sleeve. Drive lock sleeve into position. Install snap ring. Stake driven pinion lock nut. Install extension housing. Install oil deflector on case cover. Apply sealant on case cover and install cover on transfer case. Tighten bolts in crisscross pattern to specification. Install differential side gear intermediate shaft No. 2.
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