Jeep J-10 Series 1982 Technical & Service Manual page 683

Removal
(1) Raise vehicle.
(2) Remove fill and drain plugs and drain oil from
transfer case.
(3) Mark propeller shaft and transfer case yoke for
assembly alignment reference.
(4) Disconnect propeller shaft. Secure shaft to un
derside of vehicle.
(5) Remove and discard transfer case yoke retain
ing nut and yoke seal washer. Use Tool J-8614-01 to hold
yoke while removing nut.
(6) Remove yoke. If necessary, remove yoke using
Tools J-8614-01, -02 and -03.
(7) Remove speedometer driven gear sleeve and
driven gear from rear retainer.
(8) Mark rear retainer for assembly alignment
reference.
(9) Remove retainer attaching bolts and remove re
tainer. Tap retainer with rawhide or plastic mallet to
remove it.
CAUTION: Do not attempt to pry the retainer off the
rear case. Tap the retainer loose using a rawhide or
plastic mallet only.
(10) Remove speedometer drive gear.
(11) Remove pump housing from retainer and re
move seal from housing (fig. 2D-8).
(12) If retainer or bearing are to be replaced, remove
bearing retaining snap ring from rear retainer and tap
bearing out of retainer using plastic mallet.
(13) Remove oil pump from mainshaft (fig. 2D-5).
(14) Remove output shaft seal if seal is to be
replaced.
Installation
(1) Install oil pump on mainshaft.
(2) Install seal in pump housing. Be sure to install
seal so lip faces case interior. Lubricate seal lip with
petroleum jelly or 10W-30 motor oil before installation.
(3) Install speedometer driven gear.
(4) Install rear output bearing in rear retainer and
install snap ring. Be sure shielded side of bearing faces
interior of transfer case.
(5) Install pump housing in rear retainer.
(6) Apply Loctite 515, or equivalent sealant, to mat
ing surface of rear retainer.
(7) Align retainer and case reference marks and
install retainer on case.
(8) Install and tighten retainer attaching bolts to 23
foot-pounds (31 N»m) torque.
(9) Install output shaft seal.
(10) Install yoke, yoke seal washer and yoke nut.
Tighten nut to 120 foot-pounds (163 N«m) torque.
(11) Install speedometer driven gear and sleeve.
(12) Install drain plug. Tighten plug to 35 foot
pounds (47 N«m) torque.
TRANSFER CASE 2D-9
(13) Fill transfer case to edge of fill plug opening
with AMC/Jeep Automatic Transmission Fluid or
equivalent labeled Dexron II®.
(14) Install fill plug. Tighten plug to 35 foot-pounds
(47 N»m) torque.
(15) Connect propeller shaft. Tighten clamp strap
bolts to 16 foot-pounds (21 »m) torque.
(16) Lower vehicle.
DISASSEMBLY
(1) Remove fill and drain plugs (fig. 2D-9).
(2) Remove front and rear yokes. Discard yoke seal
washers and yoke nuts.
(3) Turn transfer on end and position front case on
wood blocks. Cut "V" case notches in wood blocks to
clear mounting studs in front case if necessary.
(4) Remove lock mode indicator switch and washer
(fig. 2D-9).
(5) Remove detent bolt, spring and ball (fig. 2D-10).
(6) Mark rear retainer and case for assembly align
ment reference.
(7) Remove rear retainer attaching bolts and re
move retainer and pump housing as assembly (fig. 2D-
8). Tap retainer from case using plastic mallet only. Do
not pry.
(8) Remove pump housing from retainer and re
move pump seal from housing (fig. 2D-8). Discard seal.
(9) Remove speedometer drive gear from
mainshaft.
(10) Remove oil pump from mainshaft. Note position
of pump for assembly reference. Side facing case inte
rior has recess in it (fig. 2D-11).
(11) Remove bolts attaching rear case to front case
and remove rear case.
CAUTION: To remove the rear case, insert screw
drivers into the slots cast in the case ends and gently pry
upward. Do not attempt to wedge the case halves apart
at any point on the mating surfaces.
(12) Remove front output shaft rear thrust bearing
assembly (fig. 2D-12). Note position of bearing and races
for assembly reference.
(13) Remove driven sprocket retaining snap ring (fig.
2D-13).
(14) Remove drive sprocket retaining snap ring and
remove thrust washer and spacer washer, if equipped
(fig. 2D-14).
(15) Remove drive and driven sprockets and drive
chain as assembly (fig. 2D-15). Lift evenly on both
sprockets to remove assembly.
(16) Remove front output shaft and front thrust
bearing assembly (fig. 2D-16).
(17) Remove sprocket carrier stop ring (fig. 2D-17).
(18) Remove clutch spring (fig. 2D-17).
(19) Remove sliding clutch, node fork, mode fork
spring and bracket as assembly (fig. 2D-];:). Remove
shift rail.