Full-Time 4WD

Fig. 7 Transfer Case & Transfer Control System:

Fig. 8 Extension & Center Differential. Full-time 4WD:

Refer to Figs. 7 and 8, when performing the following procedure.

Removal

1. Install transmission in suitable holding fixture.
2. Remove release lever and clutch release bearing.
3. On dual range models, remove rod arm spring pin using removal tool No. 398791600, then the front rod ball joint nut and high-low shifter rod.
4. On all models, remove transfer shifter rod snap pin, then the clevis pin.
5. Remove three differential lock cable bracket attaching bolts, then separate the bracket from case.
6. Remove three actuator attaching bolts, then the actuator and cable assembly.
7. Remove transfer cover.
8. On dual range models, remove transfer case plug.
9. On all models, remove five rear cover attaching bolts, then the rear cover and bracket.
10. Remove ten extension attaching bolts, then the center differential and extension.
11. On dual range models, remove transfer shifter rod snap ring, then the shifter rod assembly.
12. On all models, remove reverse check sleeve attaching bolts, then the reverse check sleeve.
13. Remove shifter fork screw retaining the selector arm to shifter fork arm.
14. Remove transfer case and shifter assembly, then the bearing mounting bolts.

Installation

1. Install transfer shifter rod to extension with a clip.
2. Install center differential and extension to transfer case.
3. Torque ten extension attaching bolts to 25.3-29.7 ft. lbs.
4. On dual range models, install ball, spring, gasket and plug to transfer case side. Torque plug to 7 ft. lbs. Ensure shifter rod assembly functions properly.
5. On all models, install extension cover, shifter bracket, and five attaching bolts. Torque bolts to 22.4-26.8 ft. lbs.
6. On dual range models, proceed as follows:
a. Install high-low shifter lever.
b. Install rear rod arm to high-low shifter rod, then secure with straight pin.
c. Install rod ball joint front threaded end to high-low shifter rod lever bore, then the spring washers and nuts and torque to 14 ft. lbs.
d. Place transfer shifter rod to 4WD LO position, then attach high-low fork rod to transfer case with stopper pin.
e. With rod ball joint assembly secure, turn rod adjusting screw counterclockwise, then turn it back 90° clockwise at point where ball joint movement becomes tight.
f. Tighten rear nut, then the front nut while holding rod ball joint assembly. Remove stopper pin after tightening nuts.
7. On all models, install transfer cover with gasket. Torque attaching bolts to 10.5-12.7 ft. lbs.
8. Install actuator and cable assembly, and cable plate. Torque attaching bolts to 10.5-12.7 ft. lbs.
9. While turning main shaft, position differential lock lever to the center differential lock side.
10. Connect a hose to pipe on outside of actuator, then apply vacuum, using a suitable vacuum pump, to the actuator until cable is shortened as much as possible.
11. While applying vacuum, turn turnbuckle in direction that shortens cable until it no longer turns, then back off turnbuckle 180° and torque two locknuts to 3.6 ft. lbs.
12. Apply - 9.84 inches Hg of vacuum to inner and outer actuator pipes to ensure proper operation of transfer shifter rod.