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21 - 136
TRANSFER CASE
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(10) Remove front shaft and h i g h gear.
(11) Remove i n p u t gear, bearing, seals and washer.
(12) Loosen a n d remove idler shaft w i t h plastic
m a l l e t (Fig. 8).
Fig. 8 Idler Shaft Removal
(13) T i l t case, r o l l i d l e r gear t o w a r d front shaft
opening i n case and remove gear t h r o u g h t h i s open-
i n g .
(14)
Remove a n d r e t a i n idler shaft shims. T i e
shims together to avoid losing them.
(15) Remove b e a r i n g cups and bearings from i d l e r
gear.
(16) Remove i n t e r l o c k pins from inside case. Re-
move pins t h r o u g h P T O cover opening.
(17) I f f r o n t o u t p u t shaft rear bearing m u s t be re-
placed, replace the b e a r i n g and retainer as a n assem-
b l y only.
TRANSFER CASE ASSEMBLY
L u b r i c a t e t h e transfer case gears a n d shafts w i t h
gear o i l d u r i n g assembly. Use petroleum j e l l y t o pre-
lubricate a n d h o l d bearings i n place d u r i n g i n s t a l l a -
t i o n . Use n e w gaskets and seals throughout. Do n o t
reuse these components. Replace snap rings i f dis-
torted or damaged and use new yoke locknuts t o se-
cure t h e yoke and
flange.
(1) I n s t a l l bearing cups i n idler gear w i t h shop
press (Fig. 9).
(2) Assemble idler gear, gear bearing cones, bear-
i n g spacer a n d shims o n shaft tool DD1272 (Fig. 9).
T h e n check end play (Fig. 9). E n d play should be
.000 t o .002 i n c h . A d d or remove shims as needed to
adjust end play.
*
(3) Press shift r a i l seals into case. Seals are wiper-
type and should be installed w i t h seal l i p o u t w a r d .
(4) I n s t a l l idler gear assembly a n d shaft tool i n
case t h r o u g h front bore (large end first). T i l t case a t
45 degree angle to ease bearing i n s t a l l a t i o n a t boss
(Fig. 10).
(5) I n s t a l l idler shaft. Insert shaft from large bore
side a n d d r i v e shaft into gear and bearings
w i t h
Fig. 9 Assembling/Adjusting Idler Gear And
Bearings
Fig. 10 Installing Idler Gear
heavy, soft face hammer. Remove shaft a l i g n m e n t
tool as idler shaft pushes i t out of gear and case.
(6) I n s t a l l i d l e r shaft washer a n d n e w l o c k n u t .
Check end play and free rotation. T i g h t e n l o c k n u t t o
203 N - m (150 ft-lbs).
(7) I n s t a l l f r o n t bearing and snap r i n g on i n p u t
gear.
(8) Assemble front output shaft. I n s t a l l gears, slid-
i n g clutch, bearings, t h r u s t washer p i n , t h r u s t wash-
ers, snap r i n g and retainer on front o u t p u t shaft.
(9) I n s t a l l interlock pins t h r o u g h large case bore or
PTO
opening.
(10) I n s t a l l i n p u t gear i n case. T h e n i n s t a l l s l i d i n g
c l u t c h on i n p u t gear and position shift fork i n c l u t c h .
(11) I n s t a l l rear wheel shift r a i l into case (from
back), w i t h slotted end first and detent notches fac-
i n g up (Fig. 7). Then push r a i l t h r o u g h shift fork a n d
i n t o opposite end of case.
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