Jeep J-10 Series 1982 Technical & Service Manual page 722

2D-46 TRANSFER CASE
90732
Fig. 2D-83 Checking Rear Output Shaft End Play
(27) Install front output shaft end, play shims and
cover plate (fig. 2D-79). Tighten cover plate bolts to 35
foot-pounds (47 X*m) torque.
NOTE: Apply Loctite 220, or equivalent sealant, to bolt
threads before installation.
(28) Install front output shaft front bearing race us
ing Tools J-8092 and J-29181 (fig. 2D-84).
(29) Install front output shaft yoke oil seal using
Tool J-25160.
iSO) Install shift rod oil seals using Tool J-25167 (fig.
2D-72).
(31) Install front bearing cap. Apply Loctite 515. or
equivalent sealant, to mating surface of cap before in
stallation. Use two bolts to align cap and case bolt holes
and tap cap into position on case using piastic mallet.
(32) Install and tighten bearing cap bolts to 35 foot
pounds (47 X«m) torque.
(33) Check front output shaft end play as follows:
. (a) Seat rear bearing cup against cover plate by
tapping end of front output shaft with piastic mallet.
(bi Mount dial indicator on front bearing cap
and position indicator stylus against end of output
shaft.
(O Pry shaft back and forth to check end play.
End play should be 0.001 to 0.005 inches (0.025
to 0.129 mm).
(d) If end play is not correct, remove or add
shims between cover plate and case. If shims are added,
seat rear bearing cup as outlined in step (a) before
checking end play again.
(34) Install front output shaft yoke. Tighten new
locknut to 120 foot-pounds (163 N*m) torque. Use Tool J-
S614-01 to hold yoke while tightening nut.
90781
Fig. 2D-84 Front Output Shaft Front Bearing Race Installation
(35) Insert front and rear output shaft shift forks
into case (fig. 2D-85).
(36) Install front output shaft shift rod poppet bail
and spring in front bearing cap.
(37) Compress poppet ball and spring and install
front output shaft shift rod part way in case.
(38) Insert front output shaft shift rod through shift
fork.
(39) Align setscrew hole in shift fork and rod. Install
and tighten setscrew to 14 foot-pounds (19 N«m) torque.
(40) Install rear output shaft shift rod poppet bail
and spring in front bearing cap.
(41) Compress ball and spring and install rear output
shaft shift rail part way in case.
NOTE: Before installing the shift rail, be sure thefront
output shaft shift rod is in Xeutral and that the inter
locks are seated in the front bearing cap bore.
(42) Insert rear output shaft shift rod through shift
fork.
(43) Align setscrew holes in fork and rod. Install and
tighten setscrew to 14 foot-pounds (19 N*m) torque.
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