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SPROCKET
CARRIER
NEEDLE
BEARINGS
TRANSFER CASE
2D-21
(34) Align rear retainer and case index marks and
install retainer. Install and tighten retainer bolts to 23
foot-pounds (23 N»m) torque.
(35) Install oil seal in rear retainer bore. Coat seal lip
with petroleum jelly before installation.
(36) Install washer and indicator switch. Tighten,
switch to 18 foot-pounds (24 N»m) torque.
(37) Apply small quantity of Loctite 515, or equiva
lent sealant, to detent retainer bolt and install detent
ball, spring and bolt (fig. 2D-10). Tighten bolt to 23 foot
pounds (31 N#m) torque.
(38) Install drain plug and gasket. Tighten plug to 35
foot-pounds (47 N»m) torque.
(39) Install oil seal in front case output shaft bore.
(40) Install front and rear yokes. Be sure to install
yoke, with collar on it, on front output shaft.
(41) Install yoke seal washers and yoke nuts. Tighten
nuts to 120 foot-pounds (163 N»m) torque.
(42) Pour 6 pints (3 liters) of 10W-30 motor oil into
transfer case through fill plug hole and install and
tighten fill plug to 18 foot-pounds (24 N«m) torque.
SPECIFICATIONS
90643
Specifications—Model 208 Transfer Case
Transfer Case Type
4-position, dual range,
part-time 4-wheel
Fig. 2D-39 Assembling Sprocket Carrier Components
drive unit with
integral low range
NOTE: Be Sure to install flat washers On the tWO bolts
Torque Transmittal Mode
Dual sprockets with
installed at the Opposite ends Of the case.
n
B
interconnecting drive chain
Low Range Reduction Ratio
(31) Install rear output bearing in rear retainer and
and Mode
2-6:1 through annulus gear
* ..
.
and planetary carrier assembly
install Snap ring.
^
Drive p0sitions and snift controls
2H, 4H, 4L, Neutral -
(32) Install Seal in pump housing. Apply petroleum
Ranges selected via floor-mounted
jelly tO pump housing tabs and install housing in rear
shift lever. (4-wheel drive ranges are
.
"
undifferentiated)
retainer.
Qase confjguration
Two-piece aluminum casting
(33) Apply Loctite 515, Or equivalent Sealant, tO mat-
with removable rear retainer
ing Surface Of rear retainer.
Lubricant Capacity and Type
6 pints (3 ||ter3) JeePi
Dextron II Automatic
transmission fluid
only.
90621
Torque Specifications
Service Set-To Torques should be used when assembling components. Service In-Use Recheck Torques should be used for checking a prt-tlghtened Item.
USA (ft-lbs)
Metric (N-m)
Service
Set-To
Torque
Detent Retainer Bolt
23
Drain and Fill Plugs
35
Front/Rear Yoke Nuts
120
Indicator Switch
18
Operating Lever Locknut
18
Rear Case-to-Front Case Bolts (All)
23
Rear Retainer Bolts
23
All torque values given in foot-pounds and newton-meters with dry fits unless otherwise specified.
Service
Service
In-Use
Service
In-Use
Recheck
Set-To
Recheck
Torque
Torque
Torque
20-25
31
27-34
30-40
47
40-54
90-130
163
122-176
15-20
24
20-34
14-20
24
19-27
20-25
31
27-34
20-25
31
27-34
90620
/
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