Model 207

Transfer Case Model 207 Assembly

- Bearings must be aligned with the bearing oil feed holes.

Install or Connect

Figure 19- New Process 207 Transfer Case:

Figure 20- New Process 207 Transfer Case:

Figure 40- Input Gear Bearing Installation:

Figure 41- Front Output Shaft Rear Bearing Installation:

Figure 42- Front Output Shaft Seal Installation:

Figure 43- Input Main Drive Gear Pilot Bearing Installation:

Figure 44- Dowel Pin Location:

Figure 45- Rear Output Shaft Bearing Installation:

Figure 46- Oil Pump Seal Installation:

Tools Required:

J-8092 Driver Handle
J-33826 Rear Output Bushing Installer
J-33829 Pilot Bearing Installer
J-33830 Front Input Bearing installer
J-33831 Input Seal Installer
J-33832 Front Output Rear Bearing Installer
J-33833 Output Main Bearing Installer
J-33834 Front Output Seal Installer
J-33835 Pump Housing Seal Installer
J-33843 Extension Housing Seal Installer

1. Lock plate (40) in the transfer case.
- Coat the case and the lock plate surfaces around the bolt holes with Loctite 515 or equivalent.
2. Lock plate retaining bolts (47). Tighten the bolts to 35 Nm (25 ft. lbs.).
3. Input gear roller bearings (45) into the transfer case, using J-33830 and J-8092. Press the bearings until the tool bottoms in the bore.
4. Front output shaft rear bearing (20), using J-33832 and J-8092.
5. Front output shaft front bearing (54), using J-33833 and J-8092. Press the bearing until the tool bottoms in the bore.
6. Front output shaft bearing retaining snap ring (53) in the case.
7. Front output shaft seal (52), using J-33834.
8. Input main drive gear seal (46), using J-33831.
9. Spacer (75) on the shift sector shaft.
10. Shift sector (74) in the transfer case.
11. Oil seal (57).
12. Retainer (58).
13. Shifter lever (59).
14. Nut (60). Tighten nut to 24 Nm (18 ft. lbs.).
15. Shift sector detent spring (61).
16. Spring retaining screw (55).
17. Pilot bearing (35) into the input gear (37), using J-33829 and J-8092. Press the bearing until the tool bottoms out.
18. Input gear front thrust bearing (38 and 39) in the transfer case.
19. Input gear (37) in the transfer case.
20. Planetary gear thrust washer (34) on the input gear (37).
21. Range fork (66) on the planetary assembly.
22. Planetary assembly into the transfer case.
- Make sure the thrust washer is aligned with the input gear and planetary assembly before installing the mainshaft.
24. Mode fork (69) on the synchronizer sleeve (27). Rotate until the mode fork is aligned with the range fork.
25. Shift fork shaft (73). Slide the mode fork rail down through the range fork until the shaft is seated in the bore of the transfer case.
26. Drive chain (76) on the front output shaft (21) and the drive sprocket (32).
27. Front output shaft (21) in the transfer case. Slightly raise the mainshaft to seat the output shaft in the case.
28. Magnet into the pocket in the transfer case.
29. Rear case (2) on the front case (44).
- Apply a 3 mm (1/8 inch) bead of Loctite 515 or equivalent to the mating surface of the front case.
- Align the rear case to the front case aligning dowel pins.
30. Case bolts (17).
- Install the two bolts with washers into the dowel pin holes. Tighten the bolts to 31 Nm (23 ft. lbs.)
31. Output bearing (10) into the rear retainer (7), using J-33833 and J-8092. Press the bearing until it is seated in the bore.
32. Pump seal (3) in the pump housing (4), using J-33835.
33. Pump housing (4) in the rear retainer (7).
- Apply petroleum jelly to the pump housing tabs before installation.
34. 3 mm (1/8 inch) of Loctite 515 or equivalent to the mating surface of the rear retainer.
35. Retainer (7) to the case.
36. Retainer bolts (9). Tighten the bolts to 24 Nm (18 ft. lbs.).
37. New snap ring (11) on the mainshaft.
- Pull up on the mainshaft and seat the snap ring in its groove.
38. Bushing (14) in the extension housing (12), using J-33826 and J-8092. Press the bushing in until the tool bottoms in the bore.
39. New seal (15) in the extension housing (12), using J-33843.
40. 3 mm (1/8 inch) of Loctite 515 or equivalent to the mating surface of the extension housing (12).
41. Extension housing (12) to the rear retainer (7).
42. Extension housing retaining bolts (13). Tighten bolts to 31 Nm (23 ft. lbs.).
43. New front yoke seal washer (50) in the yoke (48).
44. Front yoke (48).
45. New front yoke nut (49). Tighten the nut to 150 Nm (110 ft. lbs.).
46. Drain plug (16) and fill plug (16). Tighten plugs to 47 Nm (35 ft. lbs.).