Transfer Case Assemble
Transfer Case Assemble^ Tools Required
- J 37668-A JD 37668-A Seal Installer
- J 44636-1 JD 44636-1 Front Output Shaft Seal Installer
- J 44636-2 JD 44636-2 Front Output Shaft Seal Protector
- J 42738 JD 42738 Input Shaft Seal Installer
1. Install the mounting studs 1.16 to 1.20 inch in height.
2. Install the front output shaft bearing.
3. Install the front output shaft bearing retaining ring.
4. Install the front output shaft assembly.
5. Install the front input shaft retaining ring.
6. Install the input shaft bearing.
7. Install the input shaft bearing retaining ring.
8. Install the input shaft assembly.
9. Install the input shaft bearing retaining ring.
10. Install the clutch lever assembly.
Notice: Refer to Fastener Notice in Service Precautions.
11. Install the clutch inserts (left side shown).
^ Tighten the clutch lever inserts to 40 Nm (29 ft. lbs.)
12. Install the outer drum on the mainshaft.
13. Install the inner drum.
Important: When installing the clutch spring, make sure that the finger of the spring are pointing up non load only.
14. Install the clutch spring.
15. Install the inner drum retaining ring.
Important: When installing the clutch plates, make sure that the inner lip of the backing plate is facing down.
16. Install the backing plates.
17. Install the clutch pack assembly.
18. Adjust the clutch clearance.
19. Using a press, install the inner bearing in the thrust bearing.
20. Install the thrust bearing in the outer bearing support.
21. Install the apply plate.
22. Install the apply plate retaining ring.
23. Install the mainshaft assembly.
Important: Make sure that the relationship marks used to remove the drive chain and sprockets are aligned for the proper the installation
24. Install the drive chain and sprockets.
25. Install the drive sprocket retaining ring.
26. Install the driven sprocket retaining ring.
27. Install the oil pump retaining ring.
28. Install the oil pump pick up tube seal.
29. Install the oil pump assembly.
30. Install the oil pump wave washer.
31. Install the magnet.
32. Install the tone wheel.
33. Install the first rear output shaft bearing retaining ring.
34. Install the rear output shaft bearing.
35. Install the second rear output shaft bearing retaining ring.
36. Install the oil pump wear sleeve.
Important: Make sure that the sealing surface on the front case half and the rear case half are free of dirt and cleaning solvent.
37. Apply a small bead of sealant to the front case half (the bead should not be any larger than an 1/8 of an inch in width).
Important: Before the rear case half is installed on the mainshaft, make sure that the outer retaining ring for the rear output shaft bearing is in alignment with the access opening.
38. Insert a pair of snap ring pliers in the access opening.
39. Using the snap ring pliers, open the outer retaining ring for the rear output shaft bearing.
40. Using the snap ring pliers, open the outer retaining ring for the rear output shaft bearing,
41. Install the rear case half assembly.
42. Install the retaining bolts.
^ Tighten the retaining bolts to 30 Nm (21 ft. lbs.)
43. Using the J 42738, install the input shaft seal.
Important: When installing the rear output shaft seal, make sure that the drain hole is facing down.
44. Using the J 37668-A, install the rear output shaft seal.
45. Install the dust seal.
46. Install the J 44636-2 on the front output shaft.
47. Install the front output shaft seal on the J 44636-2.
48. Using the J 44636-1, install the front output shaft seal.
49. Install the left rear speed sensor.
^ Tighten the left rear speed sensor to 15 Nm (11 ft. lbs.)
50. Install the right rear speed sensor.
^ Tighten the right rear speed sensor to 15 Nm (11 ft. lbs.)
51. Install the front speed sensor.
^ Tighten the front speed sensor to 15 Nm (11 ft. lbs.)
52. Install the vent tube elbow (if needed).
53. Install the motor/encoder gasket.
54. Install the motor/encoder.
55. Install the motor/encoder mounting bolts.
^ Tighten the motor/encoder mounting bolts to 20 Nm (14 ft. lbs.)
56. Install the rubber plug.