Page 20
4. Set the three shaft assemblies in their correct
positions in the housing. Make sure that the gear
teeth are correctly engaged. The dog teeth on the
output shaft should be pointing up. Figure 26.
2. Use the lifting loops or eye bolts to lift the other
housing half and put it in the correct position.
3. Align the two dowels in the top and bottom of the
housing halves. Assemble the housing with bolts,
washers and nuts.
NOTE:
Use two washers with each bolt:
•
One washer under the bolt head
•
One washer under the nut
4. First tighten the bolts on each side of the two dowels
to 60-75 lb-ft (81-102 N•m).
5. Then tighten the remaining bolts to 60-75 lb-ft (81-
102 N•m).
Install Remaining Bearing Cages
1. Apply a small amount of transfer case lubricant
around the surfaces of the two remaining bearing
cages.
2. Set the bearing cage for the idler gear in position
over the bearing cone.
NOTE:
Do not install the shims at this time.
3. Align the capscrew holes of the bearing cage and the
housing. Use the match marks made at disassembly.
4. Fasten the bearing cage to the housing with two
capscrews 180 degrees apart.
5. Tighten the two capscrews to 30 lb-in (3.4 N•m) while
rotating one of the shafts in both directions.
Figure 27.
Assemble Transfer Case
Housing
WARNING
Small amounts of acid vapor are present when
applying silicone gasket material. To prevent
possible serious personal injury, make sure there
is good ventilation in the work area. If the silicone
gasket material gets in your eyes, flush your eyes
with water for 15 minutes. Have your eyes checked
by a doctor.
1. Apply a 0.125 inch (3.18 mm) diameter continuous
bead of silicone gasket material around the mounting
surface of the housing in the repair stand. Also apply
the gasket material around the edge of all the
fastener holes in the mounting surface. (See
complete instructions on page 29).
WARNING
To avoid serious personal injury and possible
damage to components, be very careful when
using lifting devices:
•
Inspect to make sure that the lifting loops or
lifting straps are not damaged.
•
Do not subject lifting loops or lifting straps to any
shock or drop loading.
!
!
Figure 26
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Figure 27
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Pro Gear and Transmission • 906 W. Gore St. Orlando, FL 32805 • 1 (877) 776-4600 / (407) 872-1901 • [email protected]