Transfer Case Assembly

INSTALL OR CONNECT
^ Tools Required:
- J 6133-01 Input Gear Bearing Installer
- J 37752 Oil Seal Installer
- J 35871 Input Gear Installer
- J 35664 Press Tube/Bearing Installer
- J 22912-01 Split Plate
- J 37757 Needle Bearing Installer
- J 37753 Bearing Installer
- J 36183 Output Rear Shaft Installer
- J 39497 Friction Ring Remover and Installer
- J 37751 Oil Seal Installer
- J 36850 Transjel(R) Transmission Assembly Lubricant





1. Front drive shift shaft C-clip, shaft stop washer, front drive shift fork spring, front drive shift fork and shaft stop washer onto front drive shift shaft; secure with front drive shift shaft C-clip.
2. Reduction shift fork onto reduction shift shaft; secure with reduction shift fork roll pin.





3. Input gear bearing onto input gear using a J 6133-01 and a press arbor.
4. Input gear C-clip onto input gear.





5. Input gear oil seal into front case using a J 37752.
6. Apply Loctite(R) 414, or equivalent, to the threaded portion of the oil guide bolt.
7. Oil guide in the rear case; secure with one bolt.
- Tighten oil guide bolt to 10 Nm (89 inch lbs.).





8. Input gear into front case using a J 35871 and a press arbor.
9. Input gear bearing C-clip onto input gear.








10. Front output shaft bearings onto front output shaft using a J 35664 with a J 22912-01 and a press arbor.





11. Front output shaft needle bearing into center case using a J 37757.





12. Front output shaft oil seal into center case using a J 37751.
13. Case gutter into center case; secure with one bolt.
- Tighten case gutter bolt to 12 Nm (106 inch lbs.).
14. Front output shaft into center case with a plastic mallet.





15. Rear output shaft front bearing onto rear output shaft using a J 37753 with the J 35664 and a press arbor.





16. Rear output shaft into center case using a J 36183.
17. Apply J 36850 to the low output gear needle bearing.





18. Low output gear needle bearing, low output gear and reduction clutch hub onto rear output shaft.
19. Reduction hub C-clip onto rear output shaft.
20. Interlock ball into center case passage and push against the interlock notch of the front drive shift shaft.
21. Front drive shift shaft, front drive shift fork, front drive clutch sleeve and front drive clutch hub onto rear output shaft in rear of center case aligning marks on the front drive clutch hub and sleeve.
22. Reduction shift shaft, reduction shift fork and reduction clutch sleeve onto rear output shaft in front of center case aligning marks on the reduction clutch hub and sleeve.
23. Apply Loctite(R) 599 RTV silicone sealer, or equivalent, to the two rubber plugs.
24. Apply a light coat of Loctite(R) pipe sealant, or equivalent, to the threaded portion of the two locating screws.
25. Two locating balls, two locating springs, two rubber plugs, two washers and two locating screws in the center case.
- Tighten locating screws to 26 Nm (19 ft. lbs.).





26. New countershaft friction ring onto countershaft using a J 39497 and a press arbor.

Important: Friction ring MUST be installed at precisely 39.5 mm (1.56-inch) from the end of the countershaft.

27. New countershaft O-ring onto countershaft.
28. Apply J 36850 to the new countershaft O-ring.
29. Apply J 36850 to the countershaft needle bearings.
30. Countershaft spacer, countershaft needle bearings and counter gear to countershaft.
31. Countershaft washer balls and washers to countershaft.
32. Countershaft assembly into the center case.
33. Apply Loctite(R) 599 RTV silicone sealer, or equivalent, to the front case and center case mating surfaces.
34. Front case to center case; secure with nine bolts.
- Tighten front case bolts to 23 Nm (17 ft. lb.).
35. Apply Loctite(R) 414, or equivalent, to the threaded portion of the countershaft plate bolt.
36. Countershaft case plate to front case; secure with one bolt.
- Tighten countershaft case plate bolt to 23 Nm (17 ft. lbs.).





37. Rear output shaft needle bearing in the rear case using the J 37757.





38. Rear output shaft oil seal into rear case using the J 37751.
39. Apply J 36850 to the shaft ball to retain it in place on the rear output shaft.





40. Rear output shaft washer ball, drive sprocket and drive chain onto rear output shaft and front output shaft.
41. Apply J 36850 to the drive sprocket needle bearing.
42. Drive sprocket needle bearing and drive sprocket bushing onto rear output shaft.





43. Rear output shaft rear bearing onto rear output shaft using the J 35664.
44. Rear output shaft rear bearing C-clip onto rear output shaft.
45. Speedometer drive gear on output rear shaft; secure with speedometer drive gear C-clip.

Measure
^ Tool Required:
- J 26900-5 Vernier Caliper





A. Rear case bearing bore depth using a J 26900-5 and a straightedge. Place a straightedge across the rear case and measure the bearing bore depth including the width of the straightedge and record the measurement.





B. Using the same straightedge and the J 26900-5, measure the height of the rear output shaft rear bearing on the rear output shaft including the width of the straightedge and record the measurement.
C. Subtract the height of the bearing on the rear output shaft from the rear case bearing bore depth to find shim clearance.
D. Select the appropriate shim thickness from the selective shim chart. Refer to SELECTIVE SHIM CHART.

Important: If shim clearance is O to 0.13 mm (0 to 0.005-inch) or less, no shim is needed.

46. Apply J 36850 to the selective shim to retain it in place on top of the rear output shaft rear bearing.
47. Selective shim to top of rear output shaft rear bearing.





48. Apply Loctite(R) 599 RTV silicone sealer, or equivalent, to the rear case mating surface.
49. Rear case to center case; secure with fifteen bolts.
- Tighten rear case bolts to 23 Nm (17 ft. lbs.).





50. Reduction shift yoke onto reduction shift shaft in rear case; secure with reduction shift yoke roll pin.
51. Apply a light coat of Loctite(R) pipe sealant, or equivalent, to the threaded portion of the select return spring bolt.
52. Select return pin, select return ball, washer, select return spring and select return spring bolt into rear case.
- Tighten select return spring bolt to 35 Nm (25 ft. lbs.).
53. Apply Loctite(R) 599 RTV silicone sealer, or equivalent, to the rear case and gearshift lever case mating surfaces.
54. Gearshift lever case to rear case; secure with five bolts.
- Tighten gearshift lever case bolts to 16 Nm (12 ft. lbs.).
55. Apply J 36850 to the speedometer driven gear case O-ring.
56. Speedometer driven gear case; secure with one bolt.
- Tighten speedometer driven gear case retaining bolt to 10 Nm (89 inch lbs.).

Inspect
- Four-wheel drive switch O-ring for cuts or damage. Replace as necessary.

57. Apply J 36850 to the four-wheel drive switch O-ring.
58. Steel ball and four-wheel drive switch into the rear case.
- Tighten four-wheel drive switch to 19 Nm (14 ft. lbs.).

Inspect
- Four-wheel drive low switch O-ring for cuts or damage. Replace as necessary.

59. Apply J 36850 to the four-wheel drive low switch O-ring.
60. Steel ball and four-wheel drive low switch into the rear case.
- Tighten four-wheel drive low switch to 19 Nm (14 ft. lbs.).