Disassembly Of Transfer Case; Cleaning And Inspection - Chevrolet 1973 Overhaul Manual

DISASSEMBLY OF TRANSFER CASE

Refer to figures IF and 13F for cross sectional and
exploded views of the transfer case.
1. Position transfer case on work bench or suitable
work table (Fig. 2F and 3F).
NOTE: If lubricant was not drained from
unit prior to removal from vehicle, remove
front output rear cover and P.T.O. cover
lower bolts and drain lubricant into waste
container.
2. Using Tool J-8614-1, loosen rear output shaft flange
retaining nut (Fig. 4F).
3. Using Tool J-8614-1, remove front output shaft
flange retaining nut, washer and flange.
NOTE: Tap dust shield rearward on shaft
(away from bolts) to obtain clearance to
remove bolts from flange and allow installa­
tion of Tool J-8614-1.
4. Remove bolts retaining front output shaft front
bearing retainer (Fig. 5F). Remove bearing retainer
and gasket from transfer case. Discard gasket.
5. Using a hoist or other suitable lifting tool, position
assembly on blocks (Fig. 6F).
6. Remove bolts retaining rear output shaft assembly
to transfer case and disengage assembly from
transfer case. Remove and discard gaskets.
7. Remove oil trough from transfer case (Fig. 7F).
8. Using snap ring pliers, remove snap ring retaining
differential carrier to input shaft (Fig. 8F). Slide
carrier unit from shaft.
NOTE: A 1-1/2" to 2" water hose band type
clamp may be installed on the input shaft at
this time to prevent loosing bearings when
removing input shaft assembly from the
range box.
9. Raise shift rail and drive out pin retaining shift
fork to rail (Fig. 9F).
10. Remove shift rail poppet ball plug, gasket spring
and ball from case (Fig. 10F). A small magnet may
be used to remove ball from case.
11. Push shift rail down, lift up on lockout clutch and
remove shift fork from clutch assembly.
12. Remove bolts retaining front output shaft rear
bearing retainer to transfer case. Tap on front of
shaft or carefully pry retainer away from case.
CLUTCHES A ND M A N U A L T R A N S M IS S IO N S
Remove retainer from shaft and discard gasket.
Recover any roller bearings which may fall from
rear cover.
NOTE: If necessary to replace rear bearing,
support cover and press bearing from cover.
Position new bearing to outside face of cover
and press bearing into cover until flush with
opening.
13. From lower side of case, remove (pry) output shaft
front bearing.
14. Disengage front output shaft from chain and
remove shaft from transfer case (Fig. 1 IF).
15. Remove bolts attaching intermediate chain housing
to range box. Lift or using a chain hoist, remove
intermediate housing from range box (Fig. 12F).
16. Remove chain from intermediate housing.
17. Remove lockout clutch, drive gear and input shaft
assembly from range box.
NOTE: A 1 1/2" to 2" hose clamp may be
installed on end of the input shaft to prevent
loosing the roller bearings (123) which may
fall out of clutch assembly if it is pulled off
the input shaft.
18. Pull up on shift rail and disconnect rail from link.
19. Remove (lift) input shaft assembly from range box.
NOTE: At this point the transfer case is
completely disassembled into its subassem­
blies. Each of these subassemblies should
then be disassembled for cleaning and
inspection.
CLEANING AND INSPECTIO N
Bearings-Place all bearings and rollers in cleaning
solution and allow to remain long enough to loosen all
accumulated lubricant. Bearings should be sloshed up
and down and turned slowly below surface of solution to
remove as much lubricant as possible. Remove bearings
and blow dry with compressed air, being careful to direct
air across bearing so that bearings do not spin.
Gears-Clean all shafts in cleaning solution
Shafts and
to remove all accumulations. Dry with compressed air.
Housings-Transfer case, cover, and hous­
Case, Cov er a nd
ings must be thoroughly cleaned in solution to remove
all accumulation of lubricant and dirt. Remove all trace
of gaskets from surfaces where used.
7 M - 6 5
OVERHAUL MANUAL