Assembly

Fig. 74 Needle Bearing Installation:

Fig. 75 Output Rear Shaft Bearing 1 Installation:

Fig. 68 Exploded View Of Transfer Case Assembly:

Fig. 76 Output Rear Shaft Installation:

1. Install center case needle bearing, using tool J-37757, Fig. 74.
2. Install center case oil seal using driver tool J-37751 or equivalents, until seal is flush with case.
3. Install oil gutter, then apply suitable Loctite to the gutter attaching bolt. Torque bolt to 3-5 ft. lbs.
4. Install rear case needle bearing, using tool J-37757, Fig. 74.
5. Install rear case oil seal using driver tool J-37751 or equivalents, until seal is flush with case. Coat seal lip with suitable grease.
6. Install output front shaft bearings using installer J-35664 and a suitable press.
7. Install output front shaft into center case.
8. Install output rear shaft bearing using driver tool J-35664 and J-37753, Fig. 75.
9. Install needle bearing, low gear and reduction clutch hub on output rear shaft, then the snap ring, Fig. 68.
10. Install output rear shaft assembly into center case using tool J-36183 or equivalent, Fig. 76.
11. Install fork to shift shaft.
12. Install front drive clutch hub and sleeve. Punch mark on hub should face rear side of vehicle.
13. Install front drive fork shaft assembly, sleeve and hub in center case, then the locating ball, spring and bolt in case.

Fig. 77 Drive Chain & Rear Sprocket Installation:

Fig. 78 Output Rear Shaft Needle Bearing & Bushing Installation:

Fig. 79 Output Rear Shaft Bearing 2 Installation:

Fig. 80 Interlock Steel Ball Installation:

Fig. 81 Reduction Shifter Assembly:

14. Install output rear shaft sprocket, then the chain, Fig. 77.
15. Install needle bearing and bushing on sprocket, then the steel ball, Fig. 78.
16. Install output rear shaft bearing using tool J-35664, support lower end of shaft using tool J-37757-2, Fig. 79.
17. Install bearing circlip, then the speedometer drive gear and circlip.
18. Install interlock steel ball, Fig. 80.
19. Install reduction clutch hub and sleeve with reduction shift shaft assembly into center case. When installing reduction shift shaft, front drive shift shaft must be in 4WD position.
20. Install locating ball, spring and bolt, Fig. 81.
21. Apply suitable sealant to rubber plug and install, Fig. 81.
22. Install steel ball, thrust washer, needle bearing and spacer to countershaft, then install countershaft into case.
23. Install countergear, steel ball and thrust washer, then the low gear needle bearing.
24. Install circlip on input gear, then press bearing on input gear using driver tool J-6133-01.
25. Install bearing retainer circlip.
26. Install front case oil seal.
27. Install input gear into front case, then the circlip.
28. Lubricate rotating parts, then clean mating surfaces of both cases.
29. Apply suitable sealant to front case mating surface, then assemble front and center cases. Ensure that input gear meshes with countergear.
30. Install front case bolts. Torque bolts to 13.5-20 ft. lbs.
31. Install countershaft plate bolt, apply suitable Loctite and torque bolt to 13.5-20 ft. lbs.
32. Check for proper operation of front driveshaft and that input gear and output shaft rotate smoothly.

Fig. 82 Checking Measurement A:

Fig. 83 Checking Measurement B:

Fig. 84 Shim Selection Chart:

Fig. 85 Shaft Yoke Installation:

33. Measure rear case dimension A as shown in Fig. 82.
34. Measure bearing height B as shown in Fig. 83.
35. Subtract measurement B from A and select suitable shim, Fig. 84.
36. Clean center and rear case mating surfaces, then apply suitable sealant and assemble cases.
37. Install case attaching bolts and torque to 13.5-20 ft. lbs.
38. Install universal joint flange, then check rotation of rear shaft to ensure it is smooth.
39. Shift reduction shift shaft to the left, then install yoke on shaft and secure with retaining pin, Fig. 85.
40. Torque locating spring bolts to 16-21.5 ft. lbs.
41. Install steel ball and 4WD switch. Torque switch to 12-16.5 ft. lbs.
42. Install gearshift lever case to rear case using suitable sealant. Torque attaching bolts to 13.5-20 ft. lbs.
43. Install gear shift lever temporarily and check operation of transmission.