Transfer Case: Service and Repair

Fig. 9 Extension Case & Components:

Fig. 10 Transfer Case & Components:

Refer to Figs. 9 and 10, when performing the following procedure.

REMOVAL
1. Remove transmission as outlined previously.
2. Remove side cover and main case.
3. Remove attaching bolts, then separate extension case and transfer bearing case from clutch housing.
4. Remove attaching bolts, then the transfer cover and gasket from transfer case side cover.
5. Remove circlip from shifter shaft, then remove washer and shifter lever.
6. Remove side cover attaching bolts, then the diaphragm cover and diaphragm.
7. Remove side cover attaching bolts, then the side cover and gasket.
8. Remove shifter rail spring plug, spring and ball from housing.
9. Remove shifter rail, together with synchronizer, through case side.
10. Tap transfer shaft assembly from case using suitable mallet.

INSTALLATION
1. Install transfer shaft assembly, together with drive pinion shim and O-ring into case. Torque attaching bolts to 13-16 ft. lbs.
2. Install bearing case and height shim, then torque bearing case attaching bolts to 20-24 ft. lbs. Ensure backlash is between .0039-.0059 inch. Adjust backlash by changing shim as required.
3. Press new seal into extension case using suitable tool.
4. Install extension case using new gasket, then torque attaching bolts to 17-20 ft. lbs.
5. Press oil seal and knock pipe into side case, then install shifter shaft into side cover.
6. Attach seal to knock pipe, then align knock pipe with transfer rail hole in clutch housing.
7. Install side cover, adjusting shim, transfer shaft bearing and gasket, then torque attaching bolts to 13-16 ft. lbs.
8. Install shifter rail and synchronizer into side cover from main case side.
9. Install diaphragm, then assemble shifter lever and washer to shifter shaft and retain with clip.
10. Install diaphragm cover to side cover.
11. Install transfer cover and gasket to clutch housing, then torque attaching bolts to 7 ft. lbs.
12. Install ball, spring and shifter rail spring plug into clutch housing and torque plug to 14 ft. lbs.