Transfer Case Assemble
Transfer Case Assemble^ Tools Required
- J 37668-A JD 37668-A Seal Installer
- J 44636-1 JD 44636-1 Front Output Shaft Seal Installer
- J 44636-2 JD 44636-2 Front Output Shaft Seal Protector
- J 42738 JD 42738 Input Shaft Seal Installer
1. Install the mounting studs 1.16 to 1.20 inch in height.
2. Install the front output shaft bearing.
3. Install the front output shaft bearing retaining ring.
4. Using the J 8092 (1) and the J 36370 (2), install the front output shaft rear bearing.
5. Using the J 42737, install the control actuator lever shaft bearing.
6. Lubricate the control actuator lever shaft bearing.
7. Install the control actuator lever shaft.
8. Install the NEW retaining ring for the control actuator lever shaft. Ensure the retaining ring is fully seated.
9. Using the J 22873 and a hydraulic press, install the tone wheel on the front output shaft.
10. Install the front output shaft assembly.
11. Install the front input shaft retaining ring.
Important: The bearing installed depth is 33 mm (1.30 in) from the tace of the gear, or just below the taper of the bore.
12. Install the pilot bearing in the input shaft. using the J8092 (1) and the J45237 (2).
13. Install the input shaft bearing.
14. Install the input shaft assembly.
15. Install the input shaft bearing retaining ring.
16. Install the input shaft retaining ring onto the input shaft.
^ Use snap ring pliers to position the retaining ring onto the input shaft.
^ During installation of the retaining ring, do not scratch/damage the seal surface area of the input shaft with the retaining ring.
17. Install the clutch lever assembly.
Notice: Refer to Fastener Notice in Service Precautions.
18. Install the clutch inserts (left side shown).
^ Tighten the clutch lever inserts to 40 Nm (29 ft. lbs.)
Important: Ensure that the shift detent plunger is seated correctly on the control actuator lever
19. Install the shift detent plunger.
20. Install the shift detent spring.
21. Lightly lubricate a NEW shift detent plunger 0-ring seal with transfer case fluid.
22. Install the 0-ring seal on the shift detent spring bolt.
23. Install the shift detent spring bolt in the front transfer case.
Tighten the shift detent spring bolt to 17 Nm (13 lb ft).
Important: The following service procedure is to be performed only it the rear output shaft is new
24. Install the rear output shaft oil restrictoi flush with the end of the shaft.
Important: In order to position the bearing at the proper depth, ensure that the double shoulder of the J36370 is against the bearing.
25. Install the clutch housing bearing, using the J8092 (1) and the J3637O (2).
26. Install the outer drum on the mainshaft.
Important: If replacing a 1st design clutch hub or 1st design clutch pressure plate with the 2nd design components, replace both the clutch hub and the clutch pressure plate. The 2nd design components have different dimensions than the 1st design. The clutch will not function properly if both component~ are not the same design level.
27. Install the 1st design (2) or 2nd design (1) clutch hub.
Important: When installing the clutch spring, make sure that the finger of the spring are pointing up non load only.
28. Install the clutch spring.
29. If 1st design, install the backing plate in the clutch housing, with the step shoulder facing down
30. Install a friction clutch pressure plate.
31. Install a steel clutch pressure plate.
32. Continue to install the friction and the steel clutch plates, alternating until 8 friction plates and 7 steel plates are installed.
33. Install the inner drum retaining ring.
Important:
^ A clutch plate shim package is necessary in order to have the proper shims available for setting up the clutch pack. Improper shimming can cause drivability concerns and failure of the transfer case.
^ The 2nd design clutch components will have a different stack up height. The J 44295-4 (3) must be used with the 2nd design clutch components.
34. Securely install the base plate (4) of the J 44295 in a vise, with the machined surface of the locating tabs facing up.
35. Install the assembled mainshaft, with the drum, the inner clutch plates, and the outer separator plates, on the base plate (4) of the J 44295.
36. Install the weight (1) of the J 44295 on top of the assembled clutch plates.
37. Place the gage block (2) of the J 44295 on one of the locating tabs of the base plate (4) of the J 44295.
38. If 1st design clutch components, using a feeler gage, measure between the gage block (2) and the weight (1) of the J44295.
39. If 2nd design clutch components, place the spacer (3) under the gage block (2).
40. If 2nd design, using a feeler gage, measure between the gage block (2) and the spacer (3).
41. Measure with the gage block (2), the spacer (3) if 2nd design, and the feeler gage on the remaining 2 locating tabs of the base plate (4).
42. Take the average of the three measurements. This is the required shim thickness.
Important: Measure the clutch shims in the center area of the shim. The shims may have a burr or ridge around the inner or outer edge causing an incorrect measurement. The available shims may not combine to the desired measurement.
43. Select the correct shim or shims from the clutch plate shim package, plus or minus 0.10 mm (0.004 in). You may use a combination of 2 shims to obtain the correct thickness.
The shims in the clutch plate shim package are the following thickness:
^ 0.30mm(0.l2in)
^ 0.56 mm (0.022 in)
^ 0.81 mm (0.032 in)
^ 1.04 mm (0.041 in)
^ 1.30 mm (0.051 in)
^ 1.55 mm (0.061 in)
^ 1.80 mm (0.071 in)
^ 2.08 mm (0.081 in)
44. Remove the weight (1) of the J 44295.
Important: After obtaining the desired thickness of shims, do not remove the clutch plates from the drum Removing and then installing the clutch plates could change the measurement
45. Install the shim or shims.
46. Using a suitable press plate and a hydraulic press, press the clutch bearing inner support in the clutch pressure plate bearing. Ensure the bearing inner bearing race is supported.
47. If 1st design, install the retaining ring in the clutch pressure plate.
48. If 1st design, install the clutch pressure plate bearing and inner support in the clutch pressure plate.
49. If 2nd design, install the clutch pressure plate bearing, with the inner support, in the clutch pressure plate.
50. If 1st design, install the clutch pressure plate spring.
51. If 1st design, align the tabs on the clutch pressure plate with the grooves in the clutch hub and install the clutch pressure plate assembly. Ensure the spring is installed in the groove of the pressure plate.
52. If 2nd design, install the clutch pressure plate plate spring.
53. If 2nd design, install the clutch pressure plate. Align the lugs of the pressure plate with the slots in the hub. The spring installs in the groove of the plate.
54. Install the apply plate retaining ring.
55. Install the mainshaft assembly.
Important: Make sure that the relationship marks used to remove the drive chain and sprockets are aligned for the proper the installation
56. Install the drive chain and sprockets.
57. Install the drive sprocket retaining ring.
58. Install the driven sprocket retaining ring.
59. Install the oil pump pick up tube seal.
60. Install the oil pump assembly.
61. It 1st design, install the oil pump screen.
62. It 1st design, install the connector on the oil pump screen.
63. If 1st design, install the oil pump suction pipe to the oil pump.
64. If 1st design, connect the oil pump suction pipe to the connector.
65. It 2nd design install the oil pump suction pipe assembly.
65.1. Install the screen in the case.
65.2. Install the suction pipe to the oil pump.
65.3. Inspect tor the 0-ring being in the proper position and not damaged.
66. Install the magnet.
67. Install the rear output shaft speed sensor reluctor wheel.
68. Install the rear output shaft bearing.
69. Install the second rear output shaft bearing retaining ring.
70. Install the oil pump wear sleeve.
Important: Make sure that the sealing surface on the front case half and the rear case half are free of dirt and cleaning solvent.
71. Apply a small bead of sealant to the front case half (the bead should not be any larger than an 1/8 of an inch in width).
Important: Before the rear case half is installed on the mainshaft, make sure that the outer retaining ring for the rear output shaft bearing is in alignment with the access opening.
72. Insert a pair of snap ring pliers in the access opening.
73. Using the snap ring pliers, open the outer retaining ring for the rear output shaft bearing.
74. Using the snap ring pliers, open the outer retaining ring for the rear output shaft bearing,
75. Install the rear case half assembly.
76. Install the retaining bolts.
^ Tighten the retaining bolts to 30 Nm (21 ft. lbs.)
77. Using the J 42738, install the input shaft seal.
Important: When installing the rear output shaft seal, make sure that the drain hole is facing down.
78. Using the J 37668-A, install the rear output shaft seal.
79. Install the dust seal.
80. Install the J 44636-2 on the front output shaft.
81. Install the front output shaft seal on the J 44636-2.
82. Using the J 44636-1, install the front output shaft seal.
83. Install the left rear speed sensor.
^ Tighten the left rear speed sensor to 15 Nm (11 ft. lbs.)
84. Install the right rear speed sensor.
^ Tighten the right rear speed sensor to 15 Nm (11 ft. lbs.)
85. Install the front speed sensor.
^ Tighten the front speed sensor to 15 Nm (11 ft. lbs.)
86. Install the vent tube elbow (if needed).
87. Install the motor/encoder gasket.
88. Install the motor/encoder.
89. Install the motor/encoder mounting bolts.
^ Tighten the motor/encoder mounting bolts to 20 Nm (14 ft. lbs.)
90. Install the rubber plug.