Rear Case and Internal Shift Components Service

TRANSFER REAR CASE ASSEMBLY (A/T) AND ASSOCIATED PARTS


REMOVAL
1. Remove the speedometer sensor (1).
2. Remove the plate (1).
3. Remove the speedometer driven gear bushing and driven gear (1).

NOTE: Apply a reference mark to the driven gear bushing before removal.





4. Remove front companion flange (2) and rear companion flange (3), using the flange companion holder J-8614-11 to remove the end nut.
5. Remove the front and rear companion flange.

NOTE: Use the universal puller to remove the rear companion flange.

6. Disconnect the actuator breather hose and transfer breather hose from control box (4).
7. Remove control box assembly (4).





8. Disconnect the actuator breather hose and 2WD-4WD actuator heat protector (5) from the 2WD-4WD actuator assembly (6).
9. Remove the 2WD-4WD actuator assembly bolts.





10. Pull the 2WD-4WD actuator assembly (6) with 2WD-4WD shift rod.





11. Off set the actuator assembly.





12. Remove the actuator assembly (6).
13. Remove transfer rear cover assembly (7) from transfer case assembly.

INSTALLATION





1. Apply the recommended liquid gasket (LOCTITE FMD 127) or its equivalent to the transfer rear case fitting faces.
2. Install transfer rear cover assembly (7) to transfer case assembly (8).
3. Perform the following steps before fitting the transfer rear case.
1. Shift the high-low shift to the 4H side.





2. The cut-away portion of the select rod head (15) should align with that of the rear case hole's stopper (16).
4. Tighten the transfer rear case bolts to the specified torque.

Torque: 37 Nm (27 ft. lbs.)

5. Shift the 2WD-4WD shift rod (17) to the 4WD side.





6. Join the rod grooves of 2WD-4WD actuator assembly (6) and shift rod (17).





7. Push the 2WD-4WD actuator assembly (6) with 2WD-4WD shift rod (17) till the shift rod (17) reaches the 2WD position.
8. Tighten the 2WD-4WD actuator bolts to the specified torque.

Torque: 19 Nm (14 ft. lbs.)

9. Connect the actuator breather hose to actuator.
10. Install actuator heat protector (5).
11. Install control box assembly (4).

Torque: 19 Nm (14 ft. lbs.)

12. Connect breather hoses to control box (4).





13. Install rear companion flange (3) and front companion flange (2), using the companion flange holder J-8614-11 to tighten the flange nuts to the transfer case.
14. Tighten the new transfer flange nuts to the specified torque.

Torque
Rear companion flange: 167 Nm (123 ft. lbs.)
Front companion flange: 137 Nm (101 ft. lbs.)








15. Use the punch J-39209 to stake the rear companion flange nut (3) at two spots.
16. Stake the front companion flange nut (2) at one spot.

NOTE: Be sure to confirm that there is no crack at the staked portion of the flange nut after staking.

17. Install the O-ring (23) to the speedometer driven gear bushing (22).
18. Install the driven gear to the speedometer driven gear bushing (22).
19. Install the speedometer driven gear assembly to the transfer rear cover.
20. Install the plate (21) to the transfer rear case and tighten to the specified torque.

Torque: 15 Nm (11 ft. lbs.)





21. Install the speedometer sensor and tighten the bolt (20) to the specified torque.

Torque: 27 Nm (20 ft. lbs.)






TRANSFER REAR COVER ASSEMBLY

Disassembly





1. Remove bearing snap ring, use a pair of snap ring pliers to remove the snap ring (3).
2. Remove the rear output shaft assembly (1) from the transfer rear cover (with oil seal) (9).





3. Remove ball bearing (8), using a bench press and the bearing remover J-22912-01.
4. Remove speedometer drive gear (7).
5. Remove ball (6).
6. Remove bearing snap ring (5), using a pair of snap ring pliers.





7. Remove rear output shaft (2) from the ball bearing (4), using a bench press and the bearing remover J-22912-01.

Inspection And Repair
Refer to "Unit Overhaul" for inspection and repair.

Reassembly
Transfer rear cover (with oil seal) (9). Oil seal replacement.
- Remove the oil seal from the transfer rear cover.
- Apply engine oil to the oil seal outer surfaces.
- Fill in recommended grease (BESCO 1-2) or equivalent in the oil seal lip.





- Use the oil seal installer J-39208 to install the rear oil seal to the transfer rear cover.





1. Install ball bearing (4) to the rear output shaft (2), using the ball bearing installer J-37223 and the adapter J-37486-A.
2. Install bearing snap ring (5), using a pair of snap ring pliers.
3. Install ball (6).





4. Install speedometer drive gear (7).





5. Use the ball bearing installer J-37223 to install the ball bearing (8).
6. Install the rear output shaft assembly (1) to the transfer rear cover (9).
7. Install bearing snap ring (3).

NOTE: The snap ring must be fully inserted into the transfer rear cover snap ring groove.

DETENT, SHIFT ARM, AND INTERLOCK PIN (TRANSFER CASE ASSEMBLY)





Disassembled View

Disassembly
1. Remove detent ball, spring and plug (1).





2. Use a spring pin remover to remove the spring pin (2) from the bridge (6).
3. Remove spring pin (3).
4. Remove spring (4).





5. Engage the 2WD-4WD sleeve with front output gear. Remove the spring pin (3) from the block (7). Remove the shift rod (5).
6. Remove shift arm (6).
7. Remove shift block (7).
8. Remove 4WD indicator switch (8).





9. Use a magnetic tool to remove the interlock pin (9) and spring (10) from the transfer case (16).
10. Remove select rod assembly (11).





11. Use a spring pin remover to remove the shift arm spring pin (12) from the shift arm (14) and shift block (15). Remove the high-low shift rod (13) from transfer case (16).
12. Remove shift arm (14).
13. Remove shift block (15) from transfer case (16).

Inspection And Repair
Refer to "Unit Overhaul" for inspection and repair.

Reassembly
1. Place shift block (15) in transfer case (116).
2. Set shift arm (14) on the High-Low sleeve.
3. Push High-Low shift rod (13) through shift arm (14) and block (14).
4. Engage the High-Low sleeve with the 4H (1) side.





5. Install the spring pin (12) to the shift block (15) and shift arm (14).
6. Install select rod assembly (11), joining its lever to shift block groove.
7. Engage the High-Low sleeve with the 4H side and install the interlock pin and spring (4) in the proper direction.
8. Place 2WD-4WD shift block in the transfer case (16).
9. Set 2WD-4WD shift arm on the 2WD-4WD sleeve.
10. Pull 2WD-4WD shift rod through 2WD-4WD shift arm and 2WD-4WD shift block.
11. Install the shift rod: 2WD-4WD (2) with interlock pin pushed in.





12. Install 4WD indicator switch and gasket (8). Tighten to the specified torque.

Torque: 39 Nm (29 Ft. lbs.)

13. Install spring (4).





14. Engage the 2WD-4WD sleeve with the 4WD side and install the spring pin (3).
15. Install spring pin (2) and bridge (2).
16. Install detent ball, spring and plug and tighten the plug to the specified torque.

Torque: 25 Nm (18 Ft. lbs.)