Transfer Case Assemble
Transfer Case Assemble
Idler Gear Shaft Front Seal Installation
Install a NEW transfer case idler gear shaft front seal (1) to transfer case. - RPO MXE
Front Wheel Drive Intermediate Shaft Seal Installation
Special Tools
* DT-305 - Remover/Installer
* DT-49953 - Seal Installer
For equivalent regional tools, refer to Special Tools (Tools and Equipment).
Install the intermediate shaft seal (3), to the rear extension housing using the DT-49953 - installer (2) with DT-305 - remover/installer (1).
Idler Gear Shaft Rear Seal Installation
Install a NEW idler gear shaft rear seal (1) to the rear extension housing. - RPO MXE
Rear Extension Locating Pin Installation
Install the rear extension housing locating pins (1), using a rubber mallet.
Input Shaft Bearing Retainer Front Seal Installation
Special Tools
* DT-305 - Remover/Installer
* DT-49952 - Installer
For equivalent regional tools, refer to Special Tools (Tools and Equipment).
Note: Install the NEW seal with the notched surface of the seal facing the installer tool.
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 NEW seal with the notched surface of the seal facing the installer tool.
2. Install the input shaft front seal (1), to the transfer case using the DT-49952 - installer (2) and DT-305 - remover/installer (3).
3. Install input shaft (3) and idler gear (2).
4. Install idler gear shaft (1) to transfer case. - RPO MXE
Input Shaft Bearing Retainer Rear Seal Installation
Special Tools
* DT-305 - Remover/Installer
* DT-49952 - Seal Installer
For equivalent regional tools, refer to Special Tools (Tools and Equipment)
1. Clean the transfer case rear extension housing threaded bolt holes. A thread repair tool may be used to clean the threads of old threadlocking material.
2. Spray thread cleaner into the holes. Refer to Adhesives, Fluids, Lubricants, and Sealers (Fluid Type Specifications).
Warning
Wear safety glasses when using compressed air in order to prevent eye injury.
3. Clean the transfer case and extension housing bolt holes with compressed air.
Note: Install the NEW seal with the notched surface of the seal facing away from the installer tool.
4. Install the input shaft rear seal (1) to the rear extension housing using the DT-49952 - installer (2) and DT-305 - remover/installer (3).
5. Install a NEW rear extension housing-to-transfer case seal (1).
6. Install the rear extension housing onto the transfer case housing.
7. Apply threadlock to the threads of the NEW transfer case-to-rear extension housing bolts. Refer to Adhesives, Fluids, Lubricants, and Sealers (Fluid Type Specifications).
Caution: Refer to Fastener Caution (Fastener Caution).
8. 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 25 Nm (18 lb ft).
2. Tighten the 10 transfer case-to-rear extension housing bolts (1) a second pass to 130°.
Rear Output Shaft Seal Installation
Special Tools
* DT-305 - Remover/Installer
* DT-49954-A - Seal Installer
For equivalent regional special tools, refer to Special Tools (Tools and Equipment).
Install the rear output shaft seal (3), using the DT-49954-A - installer (2) and DT-305 - remover/installer (1).
Front Wheel Drive Intermediate Shaft Bearing Installation
Special Tools
DT-49408 - Ring, Pinion Bearing
For equivalent regional tools, refer to Special Tools (Tools and Equipment).
1. Press on the intermediate shaft bearing (2) onto the intermediate shaft (3), using DT-49408 - ring (1) and a hydraulic press.
2. Install the transfer case intermediate shaft bearing retaining ring (2) to intermediate shaft (1), using suitable pliers.
Front Wheel Drive Intermediate Shaft Installation
Special Tools
* DT-113-2-A - Holder
* DT-305 - Remover/Installer
* DT-622-A - Transmission Bracket
* DT-48076 - Bearing Installer
* 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 shaft (2), and tap in the intermediate shaft using the DT-48076 - installer (3) with DT-305 - remover/installer (4) and a rubber mallet.
2. Remove the DT-49104 - protective collar and apply grease to the input splines of the intermediate shaft. Refer to Adhesives, Fluids, Lubricants, and Sealers (Fluid Type Specifications) for recommended grease.
Caution: Refer to Fastener Caution (Fastener Caution).
3. Install the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
4. Install the NEW shaft dirt deflector and grease seal assembly (1).
5. Remove the transfer case (3) from DT-622-A - bracket (2) and DT-113-2-A - holder (1).
Locating Bushing Installation
Install the transfer case locating bushing (1), using a rubber mallet.
Transfer Case-to-Transmission Seal Installation
1. Lubricate the NEW transfer case-to-transmission seal with ATF.
2. Install the NEW transfer case-to-transmission seal (1).
Transfer Case Vent Installation
Caution: Refer to Fastener Caution (Fastener Caution).
Install the transfer case vent (1) and tighten to 25 Nm (18 lb ft).
Fill Plug Installation
Caution: Refer to Fastener Caution (Fastener Caution).
Install a NEW transfer case fill plug (1) and tighten to 40 Nm (30 lb ft).
Oil Drain Plug Installation
Caution: Refer to Fastener Caution (Fastener Caution).
Install a NEW oil drain plug (1) and tighten to 40 Nm (30 lb ft).