New Process Model 208

Fig. 8 Exploded View Of New Process Model 208 Transfer Case:

1. Remove fill and drain plugs. Drain lubricant from transfer case.
2. Remove front and rear yokes. Discard yoke seal washers and yoke nuts.
3. Rotate transfer case and position on wood blocks with front of case resting on wood blocks. If necessary, cut ``V'' notches in blocks so front of case rests squarely on blocks.
4. Remove lock mode indicator switch and washer, Fig. 8.
5. Remove detent bolt, spring and ball.
6. Mark relationship between rear retainer and case for alignment during assembly.
7. Remove rear retainer attaching bolts, then rear retainer and pump housing as an assembly. Do not pry retainer from case. If necessary, use plastic mallet to tap retainer.
8. Remove pump housing from retainer, then pump seal from housing. Discard seal.
9. Remove speedometer drive gear from mainshaft.
10. Remove oil pump from mainshaft noting position of pump for reassembly. The side of pump facing toward inside of case is recessed.
11. Remove rear case to front case retainer bolts, then rear case from front case. To remove rear case, insert screwdriver into slots in case ends and gently pry upward. Do not attempt to wedge case halves apart at any point on mating surfaces.
12. Remove front output shaft rear thrust bearing assembly. Note position of bearing and races for reassembly.
13. Remove driven sprocket retaining snap ring.
14. Remove drive sprocket retaining snap ring, then thrust washer and spacer washer, if equipped.
15. Remove drive and driven sprockets and drive chain as an assembly. Lift evenly on both sprockets to remove.
16. Remove front output shaft and front thrust bearing assembly.

Fig. 9 Sprocket Carrier Stop Ring & Clutch Spring Replacement:

Fig. 10 Mode Fork, Spring, Bracket & Sliding Clutch Replacement:

Fig. 11 Sprocket Carriers, Bearing Retainers, Thrust Washer & Needle Bearing Replacement:

Fig. 12 Annulus Gear & Range Fork Replacement:

Fig. 13 Planetary Thrust Washer & Planetary Assembly Replacement:

Fig. 14 Mainshaft Thrust Bearing & Input Gear Replacement:

Fig. 15 Input Gear Thrust Bearing & Race Replacement:

17. Remove sprocket carrier stop ring and clutch spring, Fig. 9.
18. Remove sliding clutch, mode fork and mode fork spring as an assembly, Fig. 10, then remove shift rail.
19. Remove sprocket carrier, needle bearing upper retainer, thrust washer and mainshaft needle bearings as an assembly, Fig. 11.
20. Remove mainshaft.
21. Remove annulus gear retaining ring and thrust washer, then annulus gear and range fork as an assembly. Rotate fork counterclockwise to disengage fork lug from range sector and lift assembly from case, Fig. 12.
22. Remove planetary thrust washer and planetary assembly, Fig. 13.
23. Remove mainshaft thrust bearing from input gear, then input gear, Fig. 14. Lift gear straight up and out from case.
24. Remove input gear thrust bearing and race, Fig. 15. Note position of bearing and race for reference during assembly.
25. Remove range sector operating lever attaching nut and washer, then lever. Remove sector shaft seal and seal retainer.
26. Remove range sector.
27. Inspect lockplate. If lockplate is loose, worn or damaged, remove lockplate.
28. Remove output shaft seals from front and rear case seal bores.