Model 207

NOTE: All bearings used in the transfer case must be properly aligned to avoid blocking the oil passages. After installing bearings, check their position to make sure that oil passages are clear.

1. Install lock plate in case. Coat case and lock plate surfaces around bolt holes with Loctite 515, or equivalent. Install attaching bolts and torque to 20-30 ft. lbs.





2. Install input shaft roller bearings into case using tool J-33830 and J-8092.

3. Install front output shaft rear bearing using tools J-33832 and J-8092.

4. Install front output shaft front bearing using tools J-33833 and J-8092.

5. Install front output shaft bearing snap ring, then install the seal using tool J-33834.

6. Install input shaft seal using tool J33831.

7. Install spacer on shift sector shaft, then install sector and shift lever in case. Torque shift lever retaining nut to 15-20 ft. lbs.

8. Install shift sector detent spring and retaining bolt.

9. Install pilot bearing into input gear using tools J-33829 and J-8029.





10. Install input gear front thrust washer, thrust bearing and input gear in case.





11. Install planetary gear thrust washer on input gear and range fork on planetary assembly, then install planetary assembly into case.





12. Install mainshaft into case, ensuring that thrust washer is aligned with input gear and planetary assembly.





13. Install mode fork on synchronizer sleeve so that it is aligned with range fork, then slide mode fork down through range fork until rail is seated in bore of case.





14. Position drive chain around front output shaft and drive sprocket, then install front output shaft in case.

15. Install magnet into pocket in case.

16. Apply a 1/8 inch bead of Loctite 515 or equivalent to front case mating surface, then position rear case on front case dowel pins. Install case bolts and torque to 20-25 ft. lbs., then install two bolts and washers into the dowel pin holes.

17. Install output bearing into rear retainer using tools J-33833 and J-8092.

18. Install seal in pump housing using tool J-33835, then apply petroleum jelly to pump housing tabs and install housing in rear retainer.

19. Apply a 1/8 inch bead of Loctite 515 or equivalent to mating surface of rear retainer, then install retainer onto case. Torque bolts to 15-20 ft. lbs.

20. Install a new snap ring on mainshaft, then install bushing in extension housing using tools J-33826 and J-8092.

21. Install a new extension housing seal using tool J-33843.

22. Apply a 1/8 inch bead of Loctite 515 or equivalent to mating surface of extension housing, then install housing onto case. Torque bolts to 20-25 ft. lbs.

23. Install front yoke on output shaft using a new seal washer and nut. Torque nut to 90-130 ft. lbs.

24. Install drain and fill plugs and torque to 30-40 ft. lbs.