130. Transfer Case Installation

Transfer Case Installation

^ Tools Required
- J 36850 Assembly Lubricant (or equivalent)





1. Install the case extension seal (8) using J 36850 in order to retain.





2. Notice:
The oil dam must be installed with the oil passage notch aligned to the passage in the case. Incorrect alignment will cause oil flow stoppage and damage to the transmission.

Line up the notch (1) to the hole in the case and install the oil dam (901).





3. Install the transfer case lower brace (906).
4. Install the transfer case lower brace bolts (903). Hand tighten.





5. Caution:
This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.

Notice:
The park gear thrust bearing (695) must be retained in the park gear (696) when installing the transfer case to the transmission, or damage may occur.

Important:
When the transfer case is installed onto the transmission, there should be no gap between these parts. If a gap exists, check the park gear thrust bearing for proper retention to the park gear.

Install the transfer case assembly (908) onto the transmission case (3).





6. Install the 5 transfer case to case bolts (907, 909, 910).





7. Notice:
Do not use air powered tools in order to assemble or disassemble transmissions. Use hand tools in order to properly determine bolt tightness. Improper bolt torque can contribute to transmission repair conditions, and this information, which is vital to diagnosis, can only be detected when using hand tools.

Torque the bolts in the following sequence:

Notice:
Refer to Fastener Notice in Service Precautions.

Tighten 2 transfer case bolts (1, 2):
1. First pass 35 Nm (26 ft. lbs.)
2. Final Pass an additional 160 degrees
8. Tighten 1 transfer case bolt (3):
1. First pass 35 Nm (26 ft. lbs.)
2. Final Pass an additional 70 degrees
9. Tighten 2 transfer case bolts (4, 5):
Tighten transfer case bolts (4, 5) to 40 Nm (30 ft. lbs.).





10. Install the transfer case side brace (905) to case.
11. Install the transfer case side brace to case bolts (903). Hand tighten the bolts.
12. Torque the bolts in the following sequence (1, 2, 3, 4, 5).
Tighten the transfer case side brace bolts to 31 Nm (23 ft. lbs.).





13. Install the transfer case lower brace to case bolt (904).
Tighten the transfer case lower brace bolt to 56 Nm (42 ft. lbs.).





14. Tighten the transfer case lower brace to case bolts (903).
Tighten the transfer case lower brace bolts to 31 Nm (23 ft. lbs.).