Transfer Case: Service and Repair: Overview
Transfer gearbox, servicing
The items shown in the following illustrations can be removed with the transmission installed.
1. Socket-head bolt
^ 25 Nm (18 ft. lbs.)
2. Rear drive flange
3. Seal
^ For rear drive flange -2-
4. Bolt
^ 23 Nm (17 ft. lbs.)
^ For housing cover -5-
^ Qty.: 4
5. Housing cover
^ With vibration dampener
6. O-ring
^ Coat with gear oil
7. Circlip
^ For grooved ball bearing -8- on gear 1 (item-9-)
8. Grooved ball bearing
^ For gear-1 (item -9-)
^ Pressing off; see Fig. 1
^ Pressing on; see Fig. 2
9. Gear-1
^ For rear drive pinion set
^ If damaged, replace together with gear-2 (item -17-) only
^ To remove and install, pull together with -7- and -8- toward rear out of transfer gearbox housing-13-
10. Circlip
^ For needle bearing -11-
11. Needle bearing
^ For gear 1 (item -9-)
^ Remove only to replace
^ To replace, heat transfer gearbox housing -13- to approx. 100°C and use drift to drive needle bearing out toward rear
^ Drive in up to stop using 30-21 sleeve
12. Bolt
^ 23 Nm (17 ft. lbs.)
^ Loosen and tighten in stages and diagonally
13. Transfer gearbox housing
14. Tensioning nut
^ For rear drive flange -2-
15. Needle bearing
^ For gear-2 (item -17-)
^ Remove only to replace
^ Replacing
16. Circlip
^ To secure needle bearing -15- in transfer gearbox housing -13-
17. Gear-2
^ For rear drive pinion set
^ If damaged, replace together with gear-1 (item -9-) only
^ To remove and install, pull together with items -18-, -19- and -23- toward rear out of transfer gearbox housing -13-
18. Grooved ball bearing
^ For gear-2 (item -17-)
^ Pressing off; see Fig. 3
^ Pressing on; see Fig. 4
19. Circlip
^ To secure grooved ball bearing -18- in transfer gearbox housing -13-
20. Washer
^ For grooved ball bearing -16-
^ Clip guide plate -21- position before installing
21. Guide plate
22. Bolt
^ 10 Nm (7 ft. lbs.)
23. Circlip
^ To secure grooved ball bearing -18- onto gear 2 (item -17-).
24. Gasket
25. Torsen differential (PAT)
^ Replace completely is damaged
26. Seal
27. Magnet
28. Dowel pin
^ Qty: 2
29. Breather
^ For transfer gearbox
^ With cover attached
^ Installation position: breather must project 10 to 11 mm from housing without cover
30. Bolt
^ 23 Nm (17 ft. lbs.)
31. Intermediate flange for front final drive
32. Gasket
^ Replacing
33. Dowel Sleeve
34. Drive pinion
^ For front final drive
^ Removing and installing
35. Intermediate pinion
^ For front final drive
^ Installation position: gear marking faces transfer gearbox
36. Drive pinion
^ For front final drive
^ Installation position: gear marking faces transfer gearbox
37. Seal
^ Replacing
Fig. 1 Pressing off grooved ball bearing for gear-1
Fig. 2 Pressing on grooved ball bearing for gear-1
Fig. 3, Pressing off grooved ball bearing for gear-2
Fig. 4 Pressing on grooved ball bearing for gear-2