Transfer Case Assemble
Transfer Case Assemble
Input Shaft Seal Installation
Special Tools
* DT-305 - Remover/Installer
* DT-49093 - Seal Installer
* DT-49094 - Fitting Drift
For equivalent regional tools, refer to Special Tools Tools and Equipment.
Note: Install the seal onto the tool with the flat face of the seal facing away from the tool flange.
1. Install the input shaft front (inner) seal (1) to the transfer case using the DT-49093 - installer (2) and DT-305 - remover/installer (3).
Note: Install the seal onto the tool with the flat face of the seal facing away from the tool flange.
2. Install the input shaft front (outer) seal (1) to the transfer case using the DT-49093 - installer (2) and DT-305 - remover/installer (3).
Note: Install the seal onto the tool with the flat face of the seal facing away from the tool flange.
3. Install the input shaft rear seal (1) to the rear extension housing using the DT-49093 - installer (2) and DT-305 - remover/installer (3).
Idler Shaft Installation
Install the idler shaft (1) to the housing.
Input Shaft Installation
Special Tools
DT-49094 - Fitting Drift
For equivalent regional tools, refer to Special Tools Tools and Equipment.
1. Install the input shaft seal (2), using the DT-49094 - drift (3).
2. Install the input shaft (1) to the housing.
3. Apply 5 mm (0.2 in) bead of RTV to the sealing surface of the transfer case housing (1). Refer to Adhesives, Fluids, Lubricants, and Sealers Fluid Type Specifications.
4. Install the rear extension housing (2) onto the transfer case housing.
5. Apply threadlock to the threads of the NEW transfer case-to-rear extension housing bolts (3). Refer to Adhesives, Fluids, Lubricants, and Sealers Fluid Type Specifications.
Caution: Refer to Fastener Caution Fastener Caution.
6. Install the NEW transfer case-to-rear extension housing bolts (1).
1. Tighten the 10 transfer case-to-rear extension housing bolts (1) a first pass to 30 Nm (22 lb ft).
2. Tighten the 10 transfer case-to-rear extension housing bolts (1) a second pass to 60 degrees.
Rear Output Drive Shaft Housing O-ring Seal Installation
1. Clean the transfer case rear output drive shaft housing bolt holes. Thread repair tool may be used to clean the threads of old threadlock material.
2. Spray thread cleaner into holes. Refer to Adhesives, Fluids, Lubricants, and Sealers Fluid Type Specifications for recommended cleaners.
Warning
Wear safety glasses when using compressed air in order to prevent eye injury.
3. Install the housing shim, as required.
4. Install the transfer case rear output drive shaft housing seal (3).
5. Install the transfer case rear output drive shaft housing (2) to the transfer case.
Note: Use NEW bolts.
6. Apply threadlock to the threads of the transfer case rear output drive shaft housing bolts (1). Refer to Adhesives, Fluids, Lubricants, and Sealers Fluid Type Specifications for recommended thread locking material.
Caution: Refer to Fastener Caution Fastener Caution.
7. Install the NEW 7 transfer case rear output drive shaft housing bolts (1).
1. Tighten the NEW 7 transfer case rear output drive shaft housing bolts a first pass to 20 Nm (15 lb ft).
2. Tighten the NEW 7 transfer case rear output drive shaft housing bolts a second pass to 30 degrees.
Rear Output Drive Shaft Seal Installation
Special Tools
* DT-49061 - Seal Pilot
* DT-49097-A - Seal Installer
For equivalent regional tools, refer to Special Tools Tools and Equipment.
1. Install the DT-49061 - pilot (3) onto the rear output shaft nut (4).
2. Place the rear output drive shaft seal (2) over the DT-49061 - pilot and onto the rear output shaft housing.
3. Install the rear output drive shaft seal (2) using the DT-49097 -A - installer (1).
Rear Output Shaft Seal Dirt Deflector Installation
Special Tools
DT-49095 - Fitting Drift
For equivalent regional tools, refer to Special Tools Tools and Equipment.
Install the rear output shaft seal dirt deflector (1), using the DT-49095 - drift.
Intermediate Drive Shaft Bearing Installation
Special Tools
DT-48076 - Bearing Installer
For equivalent regional tools, refer to Special Tools Tools and Equipment.
1. Install the transfer case intermediate drive shaft bearing retaining ring (2).
2. Press on the intermediate drive shaft bearing to the intermediate drive shaft, using DT-48076 - installer and a hydraulic press.
3. Install the transfer case intermediate drive shaft bearing retaining ring (1).
Intermediate Drive Shaft Installation
Special Tools
* DT-113-2 - Bracket
* DT-622-A - Adapter
* DT-49103 - Fitting Drift
* DT-49104 - Protective Collar
For equivalent regional tools, refer to Special Tools Tools and Equipment.
1. Install the DT-49104 - protective collar (1) to the intermediate drive shaft (2), and install the intermediate drive shaft (2) using the DT-49103 - fitting drift (3) and a rubber mallet.
2. Remove the DT-49104 - protective collar and apply grease to the splines of the shaft. Refer to Adhesives, Fluids, Lubricants, and Sealers Fluid Type Specifications for the recommended grease.
3. Install the transfer case intermediate shaft retaining ring (1).
4. Remove the transfer case (3) from DT-622-A - adapter (2) and DT-113-2 - bracket (1).
Locating Bushing Installation
Install the transfer case locating bushing (1), as required using a rubber mallet.
Transfer Case-to-Transmission Seal Installation
Install the NEW transfer case-to-transmission seal (1).
Transfer Case Vent Installation
Caution: Refer to Fastener Caution Fastener Caution.
1. Install transfer case vent pipe (2) with new seal (1) to transfer case, if applicable.
2. Install transfer case vent bolt (3) and tighten to 22 Nm (17 lb ft) , if applicable.
Fill Plug Installation
Caution: Refer to Fastener Caution Fastener Caution.
Install a NEW fill plug (1) and seal and tighten to 50 Nm (37 lb ft).
Drain Plug Installation
Caution: Refer to Fastener Caution Fastener Caution.
Install a NEW drain plug (1) and seal and tighten to 50 Nm (37 lb ft).