Assembly

Fig. 25 Installing Needle Bearing To Front Drive Sprocket. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 26 Installing Pump Retainer Housing Bearing. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 27 Installing Front Output Seal. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 28 Sector W/shaft. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 29 Synchronizer Hub Assembly & Mode Fork. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 30 Oil Pump Pickup Screen Doweled Case Holes. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 31 Special Tools. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 32 Special Tools. New Process Models 231, 233 & 241 Transfer Cases:

1. Install needle bearings to drive sprocket using J-36370 and J-8092. On model 241, ensure that sprocket is flush on synchronizer side. Refer to Figs. 25 through 32 for aid in assembly of transfer case.
2. Install needle bearings in rear case half using J-36372 and J-8092. Bearings must be flush with boss on case housing.
3. Install bearing to front case half using J-9092 and J-33833 (Models 231 and 233) or J-37371 (Model 241), then install retainer.
4. Install bearing to pump retainer housing using J-33833 and J-8092.
5. Install bearing to input gear using J-36372 and J-8092.
6. Install thrust washer, carrier lock ring and retainer.
7. Install bearing to front case half using J-36372.
8. Install oil seal to rear extension using J-33843.
9. Install input bearing retainer seal in input bearing retainer using J-33831.
10. Install front output shaft seal in front case half using J-33834.
11. Install magnet in front case half.
12. Attach synchronizer hub to synchronizer sleeve along with three struts, then align reference marks previously made.
13. attach spring retainer to synchronizer sleeve, then attach main drive synchronizer stop ring to synchronizer sleeve.
14. Install drive sprocket to mainshaft.
15. Place planetary input gear assembly into annulus gear using soft faced hammer.
16. Install bearing retainer (snap ring) to input bearing. On models 231 and 233, install input bearing to front case half.

Fig. 19 Transfer Case Exploded View. New Process Models 231, 233 & 241 Transfer Cases:

17. Install input bearing retainer bolts (43), Fig. 19 and input bearing retainer to front case half. Apply RTV or equivalent to bearing retainer mating surfaces. Apply Loctite 242 or equivalent to bearing retainer bolt threads. Torque bolts to 14 ft. lbs.
18. Install sector with shaft into front case half.
19. Install shift lever O-ring, plastic washer, shift lever, washer and nut to front case half. Torque nut to 20 ft. lbs.
20. Install range shift hub and range shift fork into front case half. Rotate sector to align range shift fork.
21. Install synchronizer assembly, mode shift fork and rail into front case half.
22. Connect front output shaft to chain, then connect drive sprocket and mainshaft to chain. Mainshaft, drive sprocket , driven sprocket and chain are installed as a unit.
23. Install fork spring onto mode shift rail.
24. Install oil pickup tube, oil tube connector and pump pickup screen into rear case half, then install oil tube O-ring onto oil tube. Damaging the O-ring during assembly may result in pump failure.
25. Attach oil pump to oil pick up tube. Apply RTV or equivalent to case mating surfaces.
26. Place rear case over mainshaft and onto front case half. Ensure that oil pump is not damaged while rear case half is being installed. Install case bolts into case halves after coating bolt threads with Loctite 242 or equivalent. Longer case bolts and their washers are placed in doweled case holes. Torque bolts to 23 ft. lbs.
27. Place input bearing retainer snap ring onto mainshaft.
28. Install retainer snap ring, speedometer gear (Models 231 and 233) or speedometer tone wheel (Model 241) and retainer snap ring to mainshaft.
29. Install rear extension housing and extension housing bolts to pump retainer housing. Apply RTV or equivalent to mating surfaces. Apply Loctite 242 or equivalent to extension housing bolt threads. Torque bolts to 23 ft. lbs.
30. Install selection plunger, poppet spring, O-ring seal and poppet screw to front case half. Torque poppet screw to 23 ft. lbs.
31. Install indicator lamp switch and O-ring to front case housing. Torque switch to 17 ft. lbs.
32. Install front output flange, rubber sealing washer (75), washer (76) and flange nut. Torque nut to 110 ft. lbs.