Transfer Case Assemble
Transfer Case Assemble
Rear Extension Locating Pin Installation
Install the transfer case-to-rear extension housing locating pins (1), as required.
Input Shaft Seal Installation
Special Tools
* DT-305 - Remover/Installer
* DT-49094 - Fitting Drift
* DT-49952 - Installer
For equivalent regional tools, refer to Special Tools (Graziano-F46 - Transfer Case).
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 rear seal (1) to the transfer case using the DT-49952 - 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 seal (1) to the transfer case using the DT-49952 - 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 intermediate shaft seal (1) to the rear extension housing using the DT-49952 - installer (2) and DT-305 - remover/installer (3).
Idler Shaft Installation
Install the idler shaft (1) to the housing.
Front Wheel Drive Input Shaft Installation
Special Tools
DT-49094 - Fitting Drift
For equivalent regional tools, refer to Special Tools (Graziano-F46 - Transfer Case).
1. Install the front wheel 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 88861417 to the sealing surface of the transfer case housing (1). Refer to Adhesives, Fluids, Lubricants, and Sealers (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 (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 Shaft Housing Seal Installation
1. Clean the transfer case rear output 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 (Specifications) for recommended cleaners.
Warning
Wear safety glasses when using compressed air in order to prevent eye injury.
3. Install the transfer case rear output shaft housing seal (3).
4. Install the transfer case rear output shaft housing (2) to the transfer case.
Note: Use NEW bolts.
5. Apply threadlock to the threads of the transfer case rear output shaft housing bolts (1). Refer to Adhesives, Fluids, Lubricants, and Sealers (Specifications) for recommended thread locking material.
Caution: Refer to Fastener Caution (Fastener Caution).
6. Install the NEW 7 transfer case rear output shaft housing bolts (1).
1. Tighten the NEW 7 transfer case rear output shaft housing bolts a first pass to 20 Nm (15 lb ft).
2. Tighten the NEW 7 transfer case rear output shaft housing bolts a second pass to 30 degrees.
Rear Output Shaft Seal Installation
Special Tools
DT-49097 - Seal Installer
For equivalent regional special tools, refer to Special Tools (Graziano-F46 - Transfer Case).
Install the rear output shaft seal (1), using the DT-49097 - installer (2).
Rear Output Shaft Seal Dirt Deflector Installation
Special Tools
DT-49095 - Fitting Drift
For equivalent regional special tools, refer to Special Tools (Graziano-F46 - Transfer Case).
Install the rear output shaft seal dirt deflector (1), using the DT-49095 - drift.
Front Wheel Drive Intermediate Shaft Bearing Installation
Special Tools
DT-8790982 - Installing Ring
For equivalent regional tools, refer to Special Tools (Graziano-F46 - Transfer Case).
1. Install the transfer case intermediate shaft bearing retaining ring (2).
2. Press on the intermediate shaft bearing to the intermediate shaft, using DT-8790982 - installing ring and a hydraulic press.
3. Install the transfer case intermediate shaft bearing retaining ring (1).
Front Wheel Drive Intermediate 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 (Graziano-F46 - Transfer Case).
1. Install the DT-49104 - protective collar (1) to the intermediate shaft (2), and install the intermediate 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 (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 Seal Installation
Install the NEW transfer case-to-transmission O-ring 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 transfer case fill plug (1) and seal and tighten to 50 Nm (37 lb ft).
Oil Drain Plug Installation
Caution: Refer to Fastener Caution (Fastener Caution).
Install a NEW oil drain plug (1) and seal and tighten to 50 Nm (37 lb ft).