Disassembly and Assembly

DISASSEMBLY

(1) Remove shift lever assembly.











fig. 2D-76

(2) Remove bottom cover (fig 2D-76).

NOTE: The bottom cover has been coated with a sealent Use a putty knife to break the seal and work the knife around the bottom cover to loosen and remove it. Do not wedge the cover off.






(3) Remove front and rear yokes using Tool J-8614-O1 (fig. 2D-74). Discard yoke locknuts.






Fig. 2D-77

(4) Remove socket head screws attaching input shaft support to case and remove support, rear output shaft gear and input shaft as assembly (fig. 2D-77).

NOTE: The support has been coated with a sealant. Use a putty knife to break the seal, and work the knife around the support to loosen and remove it.

(5) Remove rear output shaft clutch sleeve from case.
(6) Remove and discard snap ring retaining rear output shaft gear on input shaft and remove gear.
(7) Remove and discard input shaft bearing snap ring.
(8) Remove input shaft and bearing from support. Tap end of input shaft with plastic mallet to aid removal.
(9) Remove input shaft bearing and end play shims from shaft using arbor press.
(10) Remove input shaft oil seal from support. Discard seal.
(11) Remove intermediate shaft lockplate bolt and lockplate (fig. 2D-76).
(12) Remove intermediate shaft. Tap shaft out of case using brass punch and plastic mallet.
(13) Remove and discard intermediate shaft 0-ring seal.
(14) Remove intermediate gear assembly and thrust washers.

NOTE: Thrust washers have locating tabs which must fit in notches in the case at assembly.

(15) Remove needle bearings and bearing spacers from intermediate gear.

NOTE: There are 48 needle bearings and three bearing spacers in the intermediate gear.

(16) Remove rear bearing cap attaching bolts and remove cap. Use plastic mallet to tap on output shaft to aid cap removal

NOTE: The rear bearing cap has been coated with a sealant Use a putty knife to break the seal, and work the knife around the cap to loosen and remove it.

(17) Remove end play shims and speedometer drive gear from rear output shaft (fig. 2D-76).
(18) Remove and discard rear output shaft oil seal Remove bearings and bearing races from rear bearing cap.






(19) Remove setscrews retaining front and rear output shaft shift forks on shift rods (fig. 2D-78).
(20) Remove shift rods. Insert punch through clevis pin holes in rods and rotate rods while pulling them out of case.

NOTE: When the shift rods are free of the front cap take care to avoid losing the shift rod poppet balls and springs.

(21) Remove shift forks from case.
(22) Remove bolts attaching front cap-to-case and remove front cap.

NOTE: The front cap has been coated with a sealant. Use a putty knife to break the seal and work the knife around the cap to loosen and remove it.

(23) Remove front output shaft and shift rod oil seals from front cap (fig 2D-76). Discard seals.
(24) Remove front bearing race from front bearing cap using Tool J-29168.






Fig. 2D-79


(25) Remove cover plate bolts and remove plate and end play shims from case (fig. 2D-79). Keep shims together for assembly.
(26) Move front output shaft toward front of case,
(27) Remove front output shaft rear bearing race from case (fig. 2D-79).






(28) Remove rear output shaft front bearing. Position case on wood blocks. Seat clutch gear on case interior surface and tap shaft out of bearing using rawhide mallet (fig. 2D-80).

NOTE: If the bearing proves difficult to remove, remove it using an arbor press and a suitable press tool to press the shaft out of the bearing.

(29) Remove rear output shaft front bearing, thrust washer, clutch gear and output shaft from case.






(30) Remove front output shaft rear bearing using arbor press and suitable press Tool (fig. 2D-81).

CAUTION: Be sure to support the case with wood blocks positioned at either side of the case bore. This is necessary to avoid damaging the case,

(31) Remove transfer case from arbor press and remove front output shaft, clutch gear and sleeve and shaft rear bearing from case.
(32) Remove front output shaft front bearing using Tool J-22912-01 and arbor press.
(33) Remove front output shaft gear from shaft.
(34) Remove input shaft rear needle bearing from rear output shaft using Tool J-29369-1. Support output shaft in vise during bearing removal,
(35) Remove shift rod thimbles, Use 3/8 drive, 7/16 socket and extension to tap shift rod thimbles out of case.

CLEANING AND INSPECTION

Clean the case and all components in solvent. Remove all old sealing material from the case and bearing cap mating surfaces. Dry all components except the bearings, using compressed air. Use caution when cleaning the case mating surfaces. Do not scratch or mar these surfaces in any way. However, minor surface irregularities can be removed with sandpaper. Do not dry any bearings with compressed air. Use clean shop towels only.

Inspect all parts for signs of excessive wear or dam- age. Replace gears that are cracked, chipped broken or excessively worn. Replace any bearings that are worn, pitted, scored, flat-spotted, or brinelled. Replace any shaft that has damaged splines, threads or bearing surfaces. Check the shift rods and rod bores in the case for wear or damage. Minor scratches or nicks on the rods may be cleaned up using crocus cloth.

ASSEMBLY

(1) Install shift rod thimbles. Apply Loctite 220 or equivalent sealant to thimbles before installation.
(2) Install front output shaft gear on front output shaft. Be sure clutch teeth on gear face shaft gear teeth.
(3) Install front bearing on front output shaft using arbor press and suitable press tool. Be sure bearing is seated against gear.
(4) Install front output shaft in case and install clutch sleeve and clutch gear on shaft.






(5) Install front output shaft rear bearing using arbor press and suitable press tool (fig. 2D-82).

NOTE: Install an old yoke nut on the shaft to avoid damaging the threads.

(6) Install input shaft rear needle bearing in rear output shaft using Tool J-29179.
(7) Position rear output shaft clutch gear in case and insert rear output shaft into gear.
(8) Install thrust washer and front bearing on rear output shaft using arbor press and suitable press tool.
(9) Install shims and bearing on input shaft using arbor press and suitable press tool.
(10) Install new input shaft oil seal in input shaft support using Tool J-29184.
(11) Install input shaft and bearing in support and install new bearing snap ring.
(12) Install rear output shaft gear on input gear and install new gear retaining snap ring (fig. 2D-77).
(13) Measure clearance between input gear and gear retaining snap ring using feeler gauge. Clearance should not exceed 0.003 inches (0.076 mm). If clearance is over tolerance, disassemble input shaft and add shims between input shaft and shaft bearing (fig. 2D-76).
(14) Install clutch sleeve on rear output shaft.
(15) Apply Loctite 515, or equivalent sealant, to mating surface of input shaft support and install assembled support, shaft and gear in case. Use two support bolts to align support on case and tap support into position using plastic mallet.
(16) Install and tighten socket head screws in support to 10 foot-pounds (14 N.m) torque.
(17) Install rear bearing cap front bearing race using Tool J-9276-3.
(18) Install rear bearing cap rear bearing race using Tool J-29182.
(19) Position rear output shaft rear bearing in rear bearing cap.
(20) Install rear output shaft yoke oil seal using Tool J-25160.
(21) Install speedometer gear and end play shims on rear output shaft.
(22) Install rear bearing cap. Apply Loctite 515, or equivalent sealant, to mating surface of cap. Use two cap bolts to align bolt holes and tap rear cap into place using plastic mallet.
(23) Install and tighten rear bearing cap bolts to 35 foot-pounds (47 N.m) torque.
(24) Install rear output shaft yoke. Tighten new lock-nut to 120 foot-pounds (163 N.m torque. Use Tool J8614-01 to hold yoke while tightening nut.






(25) Check rear output shaft end play as follows:
(a) Clamp Dial Indicator J-8001 onto bearing cap. Position indicator stylus so it contacts end of shaft (fig. 2D-83).
(b) Pry output shaft back and forth to check end play. End play should be 0.001 to 0.005 inches (0.025 to 0.127 mm).
(c) If end play is not correct, remove or add shims between speedometer drive gear and output shaft rear bearing (fig. 2D-76).
(26) Install front output shaft rear bearing race (fig. 2D-79).
(27) Install front output shaft end, play shims and cover plate (fig. 2D-79). Tighten cover plate bolts to 35 foot pounds (47 N.m) torque.

NOTE: Apply Loctite 220, or equivalent sealant, to bolt threads before installation.






(28) Install front output shaft front bearing race using Tools J-8092 and J-29181 (fig, 2D-84).
(29) Install front output shaft yoke oil seal using Tool J-25160.






(30) Install shift rod oil seals using Tool J-25167 (fig. 2D-72).
(31) Install front bearing cap. Apply Loctite 515, or equivalent sealant, to mating surface of cap before installation. Use two bolts to align cap and case bolt holes and tap cap into position on case using plastic mallet,
(32) Install and tighten bearing cap bolts to 35 foot-pounds (47 N.m) torque.
(33) Check front output shaft end play as follows:
(a) Seat rear bearing cup against cover plate by tapping end of front output shaft with plastic mallet,
(b) Mount dial indicator on front bearing cap and position indicator stylus against end of output shaft.
(c) Pry shaft back and forth to check end play. End play should be 0.001 to 0.005 inches (0.025 to .129 mm).
(d) If end play is not correct, remove or add shims between cover plate and case. If shims are added, seat rear bearing cup as outlined in step (a) before checking end play again.
(34) Install front output shaft yoke. Tighten new locknut to 120 foot-pounds (163 N.m) torque Use Tool J-614-O1 to hold yoke while tightening nut.











(35) Insert front and rear output shaft shift forks into case (fig. 2D-85).
(36) Install front output shaft shift rod poppet ball and spring in front bearing cap.
(37) Compress poppet ball and spring and install front output shaft shift rod part way in case.
(38) Insert front output shaft shift rod through Shift fork.
(39) Align setscrew hole in shift fork and rod. Install and tighten setscrew to 14 foot-pounds (19 N.m) torque.
(40) Install rear output shaft shift rod poppet ball and spring in front bearing cap
(41) Compress ball and spring and install rear output shaft shift rail part way in case.

NOTE: Before ins tailing the shift rai1, be sure the front output shaft shift rod is in Neutral and that the interlocks are seated in the front bearing cap bore.

(42) Insert rear output shaft shift rod through shift fork.
(43) Align setscrew holes in fork and rod. Install and tighten setscrew to 14 foot-pounds (19 N.m) torque.
(44) Insert Tool J-25142 in intermediate gear and install needle hearings and spacers in gear.
(45) Install intermediate gear thrust washers in case. Be sure washer tangs are aligned with grooves in case.

NOTE The thrust washers can be held in place with petroleum jelly.

(46) Install new 0-ring seal on intermediate shaft.
(47) Position intermediate gear in case.
(48) Install intermediate shaft in case bore. Tap shaft into gear until shaft forces Tool J-25142 out of case. Use plastic mallet to tap shaft into place.
(49) Install intermediate shaft lockplate and bolt. Tighten bolt to 23 foot-pounds (31 N.m) torque.
(50) Install bottom cover and replacement gasket. Apply Loctite 515, or equivalent sealant, to mating surface of cover. Install and tighten cover bolts to 15 foot-pounds (20 N.m) torque