Transfer Case Installation; Transfer Case Shift Linkage Adjustment - Jeep 1987 Wrangler Workshop Manual

GEARBOXES
TRANSFER CASE
Disconnect the transfer case vent and vacuum
hoses. Tag the hoses for assembly reference.
Disconnect the transfer case shift linkage rod
from the shift lever.
Disconnect the speedometer cable.
Support the transmission with a jack stand.
Remove the rear crossmember.
Position a transmission jack under the transfer
case. Raise the jack just enough to support the
transfer case.
Remove the transfer case-to-transmission at-
taching nuts and remove the transfer case.
TRANSFER CASE INSTALLATION
Mount the transfer case on a transmission jack
and raise the transfer case to the level of the
transmission.
Align the transfer case and transmission shaft
splines and install the transfer case. Tighten the
transfer case attaching nuts to 35 N*31m (26
ft-lbs) torque.
Connect the speedometer cable and the trans-
fer case shift linkage.
Connect the transfer case vent and vacuum
hoses.
Connect the front and rear propeller shafts.
Tighten the U-joint clamp bolts to 19 N*31m
(170 in-lbs) torque.
NOTE: Be sure to align the propeller shaft
yokes with the axle yokes according to the ref-
erence marks made during removal.
Install the rear crossmember. Tighten the
crossmember-to-frame bolts to 41 N»m (30 ft-
lbs) torque. Tighten the rear support-to-cross-
member bolts to 45 Hm (33 ft-lbs) torque.
Remove the support stands.
Fill the transfer case with Jeep Quadra-Trac
lubricant.
Adjust the transfer case shift linkage. Refer to
the procedure in this section.
Lower the vehicle.
TRANSFER CASE SHIFT LINKAGE
ADJUSTMENT
Remove the transfer case shift lever boot.
Move the shift lever (1) into two-high position.
Insert a 3 mm (1/8-in) spacer between the shift
lever and the forward edge of the shift lever
gate. Secure the lever and spacer in position.
Raise the vehicle.
Loosen the lock bolt (2) on adjusting trunnion
(3) just enough to allow linkage rod (4) to slide
freely in the trunnion.
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