Jeep J-10 Series 1982 Technical & Service Manual page 696

2D-20 TRANSFER CASE
90641
Fig. 2D-37 Input Gear. Mainshaft Thrust Bearing
and Planetary Installation
CAUTION: The shift rail bore in the case must be
completely dry and not contain any oil. A small amount
of oil may prevent the rail from seating completely and
also prevent front case installation.
(13) Install mainshaft (fig. 2D-20). Be sure main-
shaft thrust bearing is properly seated in input gear
before installing mainshaft.
(14) Coat sprocket carrier bore with liberal quantity
of petroleum jelly and position bearing retainer at cen
ter of carrier bore.
(15) Coat mainshaft needle bearings with petroleum
jelly and install 60 needle bearings in each end of
sprocket carrier bore. Total of 120 bearings are used.
(r6) Install bearing retainer in each end of sprocket
carrier bore and position thrust washer on bottom of
carrier (fig. 2D-39).
(17) Align assembled carrier and needle bearings
with mainshaft and install assembly on mainshaft (fig.
2D-16). Take care to avoid displacing needle bearings
during installation.
(18) Assemble mode fork, fork spring and bracket.
Engage fork in sliding clutch and install assembly on
shift rail and mainshaft (fig. 2D-18).
(19) Install clutch spring and stop ring on sprocket
carrier (fig. 2D-17).
NOTE: If the sprocket carrier has two ring grooves,
install the stop ring in the upper groove only.
Fig. 2D-38 Annulus Gear and Shift Rail Installation
(20) Install front output shaft front thrust bearing
assembly in front case (fig. 2D-16). Correct installation
sequence is thick race-thrust bearing-thin race.
(21) Install front output shaft.
(22) Install sprockets and drive chain as assembly.
Position sprockets in chain, align sprockets with shafts
and install assembly (fig. 2D-15).
NOTE: Be sure the drive sprocket is installed with the
recessed side of the sprocketfacing the case interior.
(23) Install spacer and thrust washer on drive
sprocket (fig..2D-14) and install sprocket retaining snap
ring.
(24) Install driven sprocket retaining ring (fig.
2D-13).
(25) Install front output shaft rear thrust bearing
assembly on front output shaft (fig. 2D-12). Correct
installation sequence is thin race-thrust bearing-thick
race.
(26) Install oil pump on mainshaft. Be sure recessed
side of pump faces downward toward case interior.
(27) Install speedometer drive gear on mainshaft.
(28) Install magnet in front case, if removed.
(29) Apply Loctite 515, or equivalent sealant, to mat
ing surface of front case and install rear case on front
case.
CAUTION: Be sure front output shaft rear thrust
bearing assembly is seated in the rear case.
(30) Align case bolt holes and alignment dowels and
install bolts. Tighten bolts alternately and evenly to 23
foot-pounds (31 N»m) torque.