VI. TRANSFER CASE ASSEMBLY
A. General Precautions
Read these instructions completely before starting
reassembly. Refer to the appropriate exploded view
(at the back of the manual). Assemble, adjust and
check in the order shown.
Parts must be clean. Gasket surfaces must be free
of old gasket material.
Select an area that will maintain the cleanliness of
the parts and the assembly. Mount the case housing
with the cover on top, cover surface in a horizontal
plane. The cover side, the front and rear of the case
should be accessible. The housing must be
restrained. The cover should be approximately 44"
above the floor. A sturdy work bench (preferably
between 24" and 28" high) or a special stand should
be used. The components of this transmission are
heavy and positioning and installing them will be
easier if the case is supported in the position
indicated, refer to Fig. 1 and Fig. 2.
Lubricate housing bores, shaft spline and bearing
mounting surfaces, sealing lips on oil seals with
Lubriplate or equal. This is necessary to reduce the
chances of galling or scoring and to provide initial
lubrication for the oil seals. Use flanged end bearing
drivers that apply equal force to both inner and outer
races of bearings when installing bearings.
If tubular or sleeve type drivers are used, apply force
to either inner or outer race or both as needed,
depending on which will put the bearing in place
without pushing through the bearing balls.
Installation of gaskets, bearing carriers, seal carriers
and caps will be simplified if two guide studs are
utilized (See Fig. 17). Guide studs may be made by
cutting the head off a 7/16-14 bolt of about 2 inches
in length. Point the non-threaded end and also slot
the end to allow a screwdriver to be used, if
necessary, for guide removal.
Universal joint yokes or companion flanges should
be coated with Lubriplate on the seal operating area
before installation. They should be tightened into
place with the locknuts tightened to the proper torque
before the cover is installed on the case and before
the shim thickness is determined for both the input
shaft and the rear output shaft. Universal joint yoke
or companion flange retaining nuts can be tightened
or loosened most easily when all components except
shift forks are in place. At that time it is possible to
engage both the direct drive and the underdrive
clutch gears and effectively lock all the shafts against
Use Permatex Form-A-Gasket #2 or equal pliable
setting sealant on bolt threads. If bolt threads are
not sealed they will leak oil.
B. Seal Carrier Assemblies
Seals supplied by Fabco are coated on the outside
and should not be coated with Permatex before
installation in their carriers. They should be coated on
the sealing lip with Lubriplate. Installation can best be
made with an arbor press. There are three or four
input/output shaft seals and, if a mechanically shifted
case, two or three shifter shaft seals, the quantity
depending on whether the case does or does not have a
PTO assembly installed.
C. Clutch Gear and Bearing Assemblies
Apply Lubriplate to the bearing bores of each of the
three clutching gears. Press the bearings into place by
applying force to the outer bearing race. Be sure to put
the spacer ring in place before installing the second
bearing in 35 tooth clutching gears (Item 22 on input
shaft and Item 12 on front output shaft).