Transfer Case: Service and Repair

Transfer Case And Control System:

Extension Section:

Removal

1. Install transmission in a suitable holding fixture.
2. Remove two clutch sleeve clips from front of transmission, then the clutch release bearing.
3. Remove release dust cover, then the release lever retainer spring, from release lever, by pushing release lever from outside of main case. Use caution not to damage clutch sleeve clips and release lever retainer spring.
4. Remove release lever.
5. Using a suitable tool, drive out transfer shifter shaft and transfer shifter lever spring pin from right side of transfer case.
6. Remove transfer shifter lever from transfer shifter shaft.
7. Remove snap pin and 8mm clevis pin, then the cable from transfer shifter lever.
8. Remove five 8mm bolts from actuator and cable, then the actuator and cable assembly.
9. Remove transfer cover attaching bolts, then the transfer cover.
10. Remove straight pin from transfer shifter fork using a suitable tool.
11. Turn transfer shifter rod 180°, then remove rod.
12. Move reverse checking sleeve .08-.12 inch (2-3mm) toward outside, then remove transfer shifter fork, transfer case check ball and check ball spring.
13. Remove seven extension attaching bolts.
14. Remove extension and transfer gear assembly.
15. Remove transfer shifter shaft from right side of transfer case.
16. Remove transfer case filler with gasket, then the reverse accent spring and ball.
17. Remove reverse check sleeve assembly attaching bolts, then move sleeve until it rotates freely.
18. Remove shifter fork screw from selector arm.
19. Remove transfer case and shifter assembly attaching bolts, then the transfer case and shifter assembly from transmission case by tapping with plastic hammer.

Installation

1. Install transfer case and shifter assembly and eight attaching bolts. Torque attaching bolts to 18 ft. lbs. Ensure gasket is installed in rear of case.
2. Install selector arm to shifter arm and secure with shifter fork screw. Torque fork screw to 7 ft. lbs.
3. Install ball, reverse accent spring, gasket and plug. Torque plug to 7 ft. lbs.
4. Shift transmission into 3rd gear position, then ensure shifter arm turns lightly toward 1st/2nd gear side but heavily toward reverse gear side.

Reverse Accent Shaft Chart:

Reverse Check Plate Chart:

5. Adjust neutral position as necessary by removing bolts holding reverse check sleeve assembly to case, move sleeve assembly outward, and place adjustment shims between sleeve assembly and case to adjust clearance, Fig. 3. When shim is removed, neutral position will move closer to reverse. When shim is added, neutral position will move closer to 1st gear. Use caution not to break O-ring when replacing shim. Also, if shims cannot adjust clearance, replace accent shaft and repeat step 4.

Fig. 5 Reverse Check Plate Adjustment:

6. Shift shifter arm to 5th and then to reverse to see if reverse check mechanism operates properly, then check to see if arm returns to neutral when released from reverse position. If arm does not return satisfactorily, replace reverse check plate, Figs. 4 and 5.
7. Install extension with transfer gasket, then the extension attaching bolts. Torque bolts to 25-30 ft. lbs. Ensure transfer drive and driven gears engage each other.
8. Apply suitable oil to nylon pawl of fork, then install transfer shifter fork to coupling sleeve, aligning cutout section of fork with arm of transfer shifter shaft.
9. Install check ball spring and ball to transfer case. Use caution not to drop ball and spring into transfer case.
10. Apply suitable oil to transfer shifter rod, then install transfer shifter rod and rod spring pin. Ensure spring pin protrudes slightly beyond holes.
11. Connect end of cable and shifter lever with clevis pin and snap pin.
12. Install actuator and three actuator attaching bolts to left side of transmission case. Torque attaching bolts to 12 ft. lbs.
13. Install cable plate, two cable plate attaching bolts and washers on transfer case. Torque attaching bolts to 12 ft. lbs.
14. Connect transfer shifter lever to transfer shifter shaft.
15. Align hole in transfer shifter lever with hole in shifter shaft, then install spring pin using suitable tools.
16. 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.
17. While applying vacuum pressure, 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.
18. Operate actuator to ensure shifting from front wheel drive to 4WD is satisfactory.
19. Install transfer cover, gasket and gasket attaching bolts. Torque attaching bolts to 13-16 ft. lbs.
20. Install retaining spring on release lever.
21. Install release lever pivot to lefthand transmission case attaching bolts. Torque attaching bolts to 12 ft. lbs.
22. Push release lever against pivot, then with lever held in position, twist it to left and right so that retaining spring moves into the stepped surface on rear of pivot. Ensure proper positioning of retainer spring through access window on case.
23. Install release bearing sleeve assembly and secure with two clutch sleeve clips.
24. Install dust release cover to case.