New Process Model 208

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

Fig. 17 Input Gear, Mainshaft Thrust Bearing & Planetary Installation:

1. Install input gear race and thrust bearing into front case, then input gear, Fig. 17. During assembly lubricate all components with 10W-30 engine oil or petroleum jelly where indicated only. Do not use any other types of lubricant.
2. Install mainshaft thrust bearing in input gear, Fig. 17.
3. Install range sector shaft seal and seal retainer, then range sector.
4. Install operating lever on range sector shaft. Install shaft washer and locknut, then torque to 18 ft. lbs.
5. Install planetary assembly over input gear and ensure assembly is fully seated and meshed with gear.
6. Install planetary thrust washer on planetary hub.
7. Install inserts into range fork, if removed.
8. Engage range fork into annulus gear and install annulus gear over planetary assembly. Ensure range fork lug is inserted fully into range sector slot.
9. Install annulus gear thrust washer and retaining snap ring.
10. Align shift rail bores in case and range fork, then install shift rail. Shift rail bore in case must be dry and not contain any oil. A small amount of oil may prevent shift rail from seating completely and also may prevent front case installation.
11. Install mainshaft. Ensure mainshaft thrust bearing is seated properly in input gear before installing mainshaft.
12. Thickly coat sprocket carrier bore with petroleum jelly and position bearing retainer at center of carrier bore.
13. Coat mainshaft needle bearings with petroleum jelly and install 60 needle bearings in each end of sprocket carrier bore.

Fig. 18 Sprocket Carrier Components Assembly:

14. Install bearing retainer in each end of sprocket carrier bore and position thrust washer on bottom of carrier, Fig. 18.
15. Align assembled carrier and needle bearings with mainshaft and install assembly on mainshaft. Use caution as not to dislodge needle bearings.
16. Assemble mode fork, fork spring and bracket. Engage fork in sliding clutch and install assembly onto shift rail and mainshaft.
17. Install clutch spring and stop ring on sprocket carrier. If sprocket carrier has two ring grooves, install stop ring in upper groove only.
18. Install front output shaft front thrust bearing assembly in front case. Proper installation sequence is: thick race, thrust bearing, then thin race.
19. Install front output shaft.
20. Install sprockets and drive chain as an assembly. Position sprockets in chain, aligning sprockets with shafts and install assembly. Ensure drive sprocket is installed with recessed side of sprocket facing toward inside of case.
21. Install spacer and thrust washer on drive sprocket, then sprocket retaining snap ring.
22. Install driven sprocket retaining snap ring.
23. Install front output shaft rear thrust bearing assembly on front output shaft. Proper installation sequence is: thin race, thrust bearing, then thick race.
24. Install oil pump on mainshaft. Ensure recessed side of pump faces toward inside of case.
25. Install speedometer drive gear on mainshaft.
26. Install magnet in front case, if removed.
27. Apply Loctite 515 sealer or equivalent to mating surface of front case, then install rear case onto front case. Ensure front output shaft rear thrust bearing assembly is properly seated in rear case.
28. Align case bolt holes and alignment dowels, then install retaining bolts and torque alternately to 23 ft. lbs. Flat washers are installed on two bolts at opposite ends of case.
29. Install rear output bearing in rear retainer, then install retaining snap ring.
30. Install seal into pump housing. Apply petroleum jelly to pump housing tabs. Install housing into rear retainer.
31. Apply Loctite 515 sealer or equivalent to mating surface of rear retainer. Align rear retainer and case alignment marks made during disassembly and install retainer.
32. Install retainer attaching bolts and torque to 23 ft. lbs.
33. Install oil seal into rear retainer bore. Coat seal lip with petroleum jelly prior to installation.
34. Install washer and indicator switch, torquing switch to 18 ft. lbs.
35. Lightly apply Loctite 515 sealer or equivalent to detent retainer bolt, then install detent ball, spring and bolt, torquing bolt to 23 ft. lbs.
36. Install drain plug and gasket, torquing plug to 18 ft. lbs.
37. Install oil seal in front case output shaft bore.
38. Install front and rear yokes. Yoke with collar is installed on front output shaft.
39. Install yoke seal washer and yoke nuts. Torque nuts to 120 ft. lbs.
40. Install 6 pints of Dexron II [1][2]ATF into transfer case through fill plug.
41. Install fill plug and torque to 18 ft. lbs.