Transfer Case: Adjustments

OUTPUT FLANGE SHIM SELECTION

This procedure is used when the output flange is replaced. Replacement of the output flange requires installation of the correct size shim to maintain bearing preload. The shim must protrude from the new output flange the same distance that the original shim protruded from the original flange.

1. Stand the original output flange on end with shim side pointing up.
2. Place original shim into groove in top of flange.
3. Place a straight edge across the shim.
4. Using feeler gauge, measure the distance between the straight edge and the top of the flange (Figure 1). Record this measurement.




Figure 1 Output Flange Shim Measurement






5. Repeat steps STEP 1 through STEP 4using the new flange and the original shim. Record this measurement.
6. If measurements are not equal, use a new shim that protrudes from new output flange. Make sure it protrudes the same amount.
7. For Example: The original shim protrudes 0.075 inch from the original output flange. Place the original shim into the new output flange. The protrusion of the shim in the new flange is 0.085 inch. This indicates that a 0.010 inch thinner shim is required to maintain the original protrusion.
8. Install output flange and torque flange nut to 244 Nm (180 ft. lbs.).
9. Check the turning torque of the pinion before installing the rear cover into the P.T.U. The turning torque should be between 2.0 Nm and 2.5 Nm (17 in. lbs. and 22 in. lbs.).