Transfer Case Assembly - Jeep 1987 Wrangler Workshop Manual

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T.C. 207
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OVERHAUL
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TRANSFER CASE ASSEMBLY
N O T E : Prelubricate all transfer c a s e s e a l s ,
b e a r i n g s a n d b e a r i n g s u r f a c e s with J e e p
automatic t r a n s m i s s i o n fluid, or equivalent
marked D e x r o n ® II, during assembly operations.
Apply a bead of Loctite 515 around the low
range lockplate bolt holes in the front c a s e and
lockplate.
Align the bolt holes in the low range lockplate
(11) and front c a s e , and install the lockplate.
Install and tighten the lockplate attaching bolts
to 34 N-m (25 ft-lbs) torque.
Install a replacement front output shaft oil seal
(4) in the front c a s e with tool J 33834.
J 33834
84401
Install a replacement input gear oil seal (12) in
the front c a s e with tool J 33831.
Install sector detent spring (69) and detent bolt
(70) in the front c a s e .
Install s p a c e r (68) on shift sector (67) and install
the sector in the front c a s e .
Install the O-ring (74) and retainer (73) on the
shift sector and seat them in the c a s e .
Install range lever (72) and range lever nut (71)
on the shift sector. Tighten the nut to 24 N-m (18
ft-lbs) torque.
Install cup plug (18) in the input gear (if not
installed previously).
Install thrust bearing w a s h e r (15) and input gear
thrust bearing (16) in the front c a s e .
Insert the input gear (17) through the thrust
bearing and w a s h e r and into the front c a s e .
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