Chevrolet 1973 Overhaul Manual page 275

7 M - 5 6 CLUTCHES A N D M A N U A L T R A N S M IS S IO N S
Fig. 1 5 D -ln s ta llin g Front O utput Shaft Seal
13. Install front output shaft retainer bolts. Torque to
30 ft lbs.
14. Install front output shaft retainer seal using Tool
J-22833 as shown in Figure 15D.
15. If shift rail cups are damaged or have been
removed, position new cup in case bore and install
by tapping on end of cup.
CAUTION: Distorted cups may permit leakage
and interfere with shift rail operation.
16. Install front output shaft yoke, washer and locknut.
CAUTION: Locknut must be torqued to 250 ft.
lbs. before installing prop shaft during unit
installation.
17. Using dummy shaft J-23419, install needle bearings
and spacers in intermediate gear. Position thrust
washers in case with tang in groove on case and
supporting intermediate gear in case, installing
intermediate shaft through rear of case as shown in
Figure 16D.
CAUTION: Intermediate shaft is a press fit into
the case front bore. Align lock plate slot in
shaft with bolt hole before installing shaft in
front bore. Use care not to damage shaft "O"
ring.
18. Install intermediate shaft lock plate and bolt.
Torque bolt to 15 ft. lbs.
19. Install rear output shaft bearing assembly. Torque
retaining bolts to 30 ft. lbs.
J-22833
bearings when engaging input shaft pilot.
20. Install rear output shaft yoke, washer and locknut if
not previously done under reassembly of the sub-
assembly.
to 200-250 ft. lbs. before checking end play and
before installing the rear prop shaft.
21. Shift transfer gears. Check gear engagement and
shift rail movement. The four-wheel drive rail will
have the greater poppet ball spring tension.
22. Position bottom cover and gasket to case. Install
cover bolts and torque to 15 ft. lbs.
23. After the complete rebuild of the parts, and bearing
retainer caps into unit, check the rear and front
output shafts end play for .001 to .005 inch. Add or
remove shims at the proper location on rear output
bearing cap taper bearing, and the front output
rear bearing cover. To obtain proper specified end
play, checking of the end play of shafts is
important. It controls the seating of all the taper
bearings in the transfer case during the operation
in the vehicle. Improper end play can shorten the
life of the taper bearings in the unit.
NOTE: When installing transfer case in
vehicle, yoke locknuts may be torqued after
placing transmission in 1st gear and transfer
case in front-wheel drive.
A L I N E S H A F T S L O T
W IT H BOLT H O L E
Fig. 1 6 D -In s ta llin g In te rm e d ia te Shaft
CAUTION: Use care to prevent damage to pilot
CAUTION: Rear yoke locknut must be torqued
OVERHAUL MANUAL