2. Cleaning and Inspection (Clutch Pack Shim Procedure)

1. With the clutch drum full and on the main shaft, position the rear section of the main shaft through the hole of a flat fixture or surface.
- The fixture must be a machined flat fixture or surface.
- The hole in the fixture should be large enough to allow the rear of the shaft to fit through the hole with the bottom of the clutch drum sprocket flange resting on the flat surface.
- Ensure the clutch drum has all the inner clutch plates and outer separator plates required for the clutch drum.
- The NV 136 transfer case has eight clutch and separator plates.
- The NV 246 transfer case has ten clutch and separator plates.
- Ensure the existing clutch plate shim(s) are not installed in the clutch drum.





2. Using a micrometer, measure the thickness of the machined flat disk (3).
3. Record the measurement.
4. Take two additional disk measurements at 120° apart from each other and record the measurements.
5. Take the average the three recorded measurements.
Use this average as the thickness measurement of the machined flat disk.
6. Position a disk (3) that will fit over the top of the main shaft and rest on the top inner clutch plate.
- The disk (3) being used must be machined round and flat to be used for an accurate measurement.
- Ensure the flat disk is resting on the top inner clutch plate only, and not resting on the inner drum.
- Ensure the bottom of the mainshaft clutch drum sprocket flange is resting on the flat surface (4).

7. Their should be a small gap between the flat disk (3) and the clutch outer drum (5).
8. Position 100 pounds (45.4 Kilograms) of weight disks (1) and (2) on top of the flat disk (3).
- The weight being used may vary no more than plus or minus 10%.
- The disk weight(s) do not need to be machined round and flat.





9. Using a height gage, measure the from the top of the flat machined disk (1) to the flat machined fixture surface (2).
10. Record the measurement.
11. Take two additional measurements at 120* apart from each other and record the measurements.
12. Take the average of the three recorder measurements.
Use this average as the distance measurement from the top of the flat machined disk to the flat machined fixture surface.
13. Subtract the (flat disk thickness) measurement from the (top of the flat machined disk to the flat machined fixture surface) measurement.
(Top of the flat machined disk to the flat machined fixture surface measurement) - (flat disk thickness measurement).
The remaining distance is the distance gap between the top of the outer clutch drum and the inner clutch plate.
14. The gap size needs to be between 4.025 to 4.035 inch (102.235 to 102.489 millimeters).





15. Add shims to the top of the inner clutch plate as necessary to increase the gap to the required tolerance.
16. Repeat the procedure with the shims installed to ensure the tolerance is obtained.