Steps 35 - 68
Transfer Case Assemble Con't35. Install the O-ring seal on the shift detent spring bolt.
36. Install the shift detent spring bolt in the front transfer case.
^ Tighten the shift detent spring bolt to 17 Nm (13 ft. lbs.).
Important: The following service procedure is to be performed only if the rear output shaft is new.
37. Install the rear output shaft oil restrictor flush with the end of the shaft.
38. Install the clutch housing bearing, using the J 8092 (1) and the J 36370 (2).
39. Install the clutch housing on the rear output shaft.
40. Install the clutch hub.
Important: The fingers of the clutch hub spring face up.
41. Install the clutch hub spring.
42. Install the clutch backing plate in the clutch housing with the notch in the plate facing down.
43. Install a friction clutch pressure plate.
44. Install a steel clutch pressure plate.
45. Continue to install the friction and the steel clutch plates, alternating until 8 friction plates and 7 steel plates are installed.
46. Install the clutch hub retaining ring.
Important: A clutch plate shim package is necessary in order to have the proper shims available for setting the correct clutch pack preload. Improper preload can cause driveability concerns and failure of the transfer case.
47. Securely install the base plate (3) of the J 44295 in a vise with the machined surface of the locating tabs facing up.
48. Install the assembled rear output shaft with the clutch housing, the inner clutch plates, and the outer separator plates on the base plate (3) of the J 44295.
49. Install the weight (1) of the J 44295 on top of the assembled clutch plates.
50. Place the gage block (2) of the J 44295 on one of the locating tabs of the base plate (3) of the J 44295.
51. Using a feeler gage, measure between the gage block (2) and the weight (1) of the J 44295.
52. Measure with the gage block (2) and the feeler gage on the remaining two locating tabs of the base plate (3).
53. The average of the three measurements is the required shim thickness.
Important: Measure the clutch shims in the center area of the shim. The shims may have a burr or ridge around the inner or outer edge causing an incorrect measurement. The available shims may not combine to the desired measurement.
54. Select from the clutch plate shim package the correct shim or shims plus or minus 0.10 mm (0.004 inch). You may use a combination of two shims to obtain the correct thickness.
The shims in the clutch plate shim package are the following thickness:
^ 0.30 mm (0.12 inch)
^ 0.56 mm (0.022 inch)
^ 0.81 mm (0.032 inch)
^ 1.04 mm (0.041 inch)
^ 1.30 mm (0.051 inch)
^ 1.55 mm (0.061 inch)
^ 1.80 mm (0.071 inch)
^ 2.08 mm (0.081 inch)
55. Remove the weight (1) of the J 44295.
Important: After obtaining the desired thickness of shims, do not remove the clutch plates from the clutch housing. If you remove, and then reinstall the clutch plates, it could change the measurement.
56. Install the shim or shims.
57. Using a suitable press plate and a hydraulic press, press the clutch pressure plate bearing hub in the clutch pressure plate bearing. Ensure the bearing inner bearing race is supported.
58. Install the clutch pressure plate bearing and hub in the clutch pressure plate.
59. Install the clutch pressure plate spring.
60. Align the tabs on the clutch pressure plate with the grooves in the clutch hub and install the clutch pressure plate assembly, Ensure the spring is installed in the groove of the pressure plate.
61. Install the clutch pressure plate retaining ring. Push down on the pressure plate to access the retaining ring groove.
62. Align the tab on the clutch pressure plate bearing hub with the clutch lever.
63. Align the rear output shaft teeth to the planetary carrier and range sleeve teeth.
64. Install the rear output shaft assembly.
Important: Ensure to align the marks of the drive chain and sprockets if reusing the chain and sprockets.
65. Install the drive chain and sprockets.
66. Install the drive sprocket retaining ring.
67. Install the driven sprocket retaining ring.
68. Install the oil pump seal.