Case Cover

CASE COVER





1. Position cover on bed of suitable press so that open face of cover is up and parallel with press bed.
2. Position end of needle bearing with identification marking up and press into cover until upper end of bearing is 1.593 - 1.603 inch (40.47 - 40.97 mm) below face of cover that mates with transfer case.
3. Press in ball bearing to bottom in cover and install snap ring.





4. On electric shift units only, install parts as follow:
1. Verify that four O-rings (one on wire and one each on three studs) are in place on clutch coil assembly. Install clutch coil assembly in inside of cover, with electrical wire and studs extending through cover, with electrical wire and studs extending through cover. Use care not to kink or trap electrical wire under clutch coil assembly. Attach with three nuts and torque to 6 - 8 ft. lbs. (8 - 11 Nm).
2. Install motor bearing and oil seal in cover.
5. Install return spring over rail shaft in transfer case to rest on shift fork.
6. Install magnet in slot in transfer case.





7. Apply continuous 1/16 inch (1.6 mm) bead of sealant (Neutral Cure RTV, Loctite 598) all around transfer case mounting face for cover assembly. Center sealant bead between edges of face. Circle bolt holes. Remove excess if sealant bead is larger than 1/16 inch (1.6 mm).
8. Install cover assembly on transfer case. All of the following alignment conditions must be met for the cover assembly to seat on transfer case properly.
1. Cover holes with transfer case dowel pins.
2. Cover bearings with output shafts.
3. Blind hole in cover with rail shaft. Make sure spring in not cocked. On electric shift, check with pen light through cover hole for speed sensor.
4. On electric shift units, cover bearing with shift shaft.
9. Install nine bolts positioning identification tag and wiring clip under bolt heads at locations. Torque bolts to 20 - 34 ft. lbs. (27 - 46 Nm).
10. Install speed gear over spline of output shaft into cover assembly.





11. Press new oil seal into cover assembly.