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TRANSFER CASE
21-137
(12) I n s t a l l front o u t p u t shaft i n case.
(13) I n s t a l l front wheel shift fork i n sliding c l u t c h
on front shaft. T h e n i n s t a l l f r o n t wheel shift r a i l i n t o
case and t h r o u g h shift fork.
(14) Secure shift forks to shift r a i l s w i t h new lock
pins. I n s t a l l pins t h r o u g h s m a l l bores at top of case.
(15) I n s t a l l f r o n t o u t p u t shaft bearing retainers. B e
s u r e oil d r a i n slot i n b e a r i n g r e t a i n e r i s a l i g n e d
w i t h d r a i n hole i n c a s e before tightening bolts.
Use new gaskets and apply sealer to bolt threads be-
fore i n s t a l l a t i o n . Use e x t r a gasket on retainers i f
necessary.
(16)
I n s t a l l flange
on f r o n t shaft. I n s t a l l seal
washer on shaft and i n s t a l l flange locknut
finger
t i g h t .
(17) I n s t a l l washer, seals gasket and adapter on i n -
p u t shaft (Fig. 4).
(18) I n s t a l l shift l i n k and l i n k r e t a i n i n g pins, clips.
(19)
Assemble rear o u t p u t shaft. I n s t a l l gears,
bearings a n d spacers (Fig. 4).
(20) I n s t a l l new snap r i n g . Tap r i n g to seat i t and
check end play. E n d play should be .05 to .68 m m
(.002 to .027 i n ) .
(21) I n s t a l l p i l o t bearing rollers i n rear o u t p u t
shaft. Use as m u c h petroleum j e l l y as needed to hold
bearing rollers i n place.
(22) I n s t a l l p i l o t bearing t h r u s t washer and new
snap r i n g .
(23) I n s t a l l retainer on rear o u t p u t shaft i n s t a l l
speedometer gear and spacer, i n s t a l l bearing
(Fig.
11).
(24) I n s t a l l r e t a i n e r and shaft assembly. B e s u r e
oil d r a i n s l o t i n r e t a i n e r i s a l i g n e d w i t h d r a i n
hole i n c a s e . Use one or t w o retainer gaskets de-
Fig. 11 Assembling Rear Retainer And Output Shaft
pending on clearance. Tighten retainer bolts to 54
N*m (40 ft-lbs).
(25) I n s t a l l seals i n front and rear seal retainers.
Position gaskets on case and i n s t a l l retainers over
shafts and against case. Tighten bolts to 54 N n n (40
ft-lbs).
(26) I n s t a l l yoke and
flange.
T i g h t e n yoke a n d
flange
nuts to 176 N* (130 ft-lbs).
(27) I n s t a l l detent balls, springs, plugs, cup plugs
and 4 W D indicator l i g h t switch.
(28) I n s t a l l d r a i n plug.
(29) F i l l transfer case w i t h proper l u b r i c a n t to bot-
t o m of fill p l u g hole.
(30) I n s t a l l fill p l u g .
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