Recommended Order of Repair
DISASSEMBLY OF TRANSFER CASEDisassemble transfer case to subassemblies
DISASSEMBLY OF TRANSFER CASE SUBASSEMBLIES
Disassemble transfer case subassemblies completely in the following order:
1. High/Low Cross Shaft Housing
2. Front Output Housing
3. Rear Output Housing
4. Main Casing
5. Mainshaft Input Gear Bearing Housing
6. Intermediate Gears.
7. Mainshaft Input Gear Assembly
8. Differential Lock Selector
9. Differential
CLEANING AND INSPECTION
Clean all components thoroughly.
Inspect all components for damage and/or wear.
Replace components as necessary
SUBASSEMBLY OVERHAUL AND ASSEMBLY
Assemble Subassemblies In The Following Order:
1. Differential
2. Main Casing
3. Mainshaft Input Gear Bearing Housing
4. Mainshaft Input Gear Assembly
5. Intermediate Gears.
6. Rear Output Housing
7. Front Output Housing
8. High/low Cross Shaft Housing
9. Differential Lock Selector
10. Set input gear bearing pre-load.
ASSEMBLY OF TRANSFER CASE
Assemble Transfer Case In The Following Order:
1. Mainshaft Input Gear Bearing Pre-Load
2. Rear Output Housing
3. Differential Bearing Pre-Load
4. Front Output Housing
5. Intermediate Gears
6. Intermediate Gear Bearing Pre-Load
7. Bottom Cover
8. High/Low Selector Shaft Detent
9. Interlock Solenoid
10. Neutral Warning Lamp Switch
11. Differential Lock Warning Lamp Switch-Adjustment
12. Transmission Brake
NOTE: Lubricate all components with recommended oil.