Model 20 Transfer Case Out-Of-Vehicle Service; Transfer Case Removal; Transfer Case Installation; Transfer Case Disassembly - Jeep 1979 CJ-5 Technical & Service Manual

20-6 TRANSFER CASE
REAR B E A R I N G CAP R E A R PROPELLER
R E A R OUTPUT S H A F T
Fig. 20-11 Measuring Rear Bearing Cap End Play
(2) Connect speedometer cable.
(3) Connect propeller shaft to yoke and tighten U-
bolts to 15 foot-pounds (20 N«m) torque. If equipped
with, ball and trunnion-type propeller shaft, tighten
flange bolts to 30 foot-pounds (41 N*m) torque.
OUT-OF-VIHiCLE SERVICE - • ' • •'
Transfer Case Removal—-All Molels
(1) Remove shift lever knob, trim ring, and boot
from transmission and transfer case shift levers.
(2) Remove floor covering, if equipped, and remove
transmission access cover from floorpan.
(3) Raise vehicle and drain lubricant from transfer
case. On CJ models, drain transmission lubricant also.
(4) Disconnect torque reaction bracket from cross-
member, if equipped.
(5) On CJ models, position support stand under
clutch housing to support engine and transmission and
remove rear crossmember.
(6) Disconnect front and rear propeller shafts at
transfer case. Mark propeller shaft yokes for assembly
reference.
(7) Disconnect speedometer cable at transfer case.
(8) On Cherokee and Truck models, disconnect
parking brake cable at equalizer and disconnect exhaust
pipe support bracket at transfer case.
(9) Remove bolts attaching transfer case to trans-
mission and remove transfer case. Remove transfer case
gasket.
NOTE: One transfer case attaching bolt must be re-
moved from the front end of the case. This bolt is located
at the bottom right corner of the transmission.
Transfer Case Installation
(1) Install transmission-to-transfer case gasket on
transmission.
(2) Shift transfer case to 4L position.
(3) Install a 3/8-16 by 4 inch (10.1 cm) long dowel
pin at each side of transmission to assist in guiding
transfer case into place during installation.
(4) Position transfer case on dowel pins.
(5) Rotate transfer case output shaft (by turning
yoke) until transmission main shaft gear engages trans-
fer case rear output shaft sliding gear. Move transfer
case forward until case seats against transmission.
CAUTION: Be sure the transfer case is flush against
the transmission. Severe damage to the transfer case
will result if the attaching bolts are tightened while the
transfer case is cocked or in a bind.
(6) Install two transfer case attaching bolts but do
not tighten completely.
(7) Remove dowel pins and install remaining trans-
fer case attaching bolts. Tighten all bolts to 30 foot-
pounds (41 N®m) torque.
(8) On CJ models, fill transmission and transfer
case with SAE 90W gear lubricant, grade API GL-4.
(9) On Cherokee and Truck models, check and cor-
rect transmission fluid level as necessary. If fluid must
be added, use SAE 90W gear lubricant, grade API GL-4.
(10) Connect speedometer driven gear to transfer
case.
(11) Connect front and rear propeller shafts to trans-
fer case. Be sure to align shafts-to-yokes using reference
marks made during removal. Tighten shaft-to-yoke
clamp strap nuts to 15 foot-pounds (20 N*m) torque. If
equipped with ball and trunnion-type propeller shaft,
tighten flange bolts to 30 foot-pounds (41 N # m ) torque.
(12) On CJ models, install rear crossmember and
remove support stand from under clutch housing.
(13) On Cherokee and Truck models, connect parking
brake cable to equalizer and connect exhaust pipe sup-
port bracket to transfer case.
(14) Connect torque reaction bracket, if equipped.
(15) Lower vehicle.
(16) Install transmission access cover plate on floor-
pan. Install floor covering if equipped.
(17) Install boots, trim rings, and shift knobs.
Transfer Case Disassembly
(1) Remove shift lever assembly,
(2) Remove bottom cover and gasket (fig. 2D-12).
(3) Remove bolts attaching rear bearing cap assem-
bly to transfer case and remove assembly (fig. 2D-12).
NOTE: Refer to Rear Bearing Cap-Speedometer Drive
Gear Service for overhaul procedures.
(4) Remove intermediate shaft lock plate (fig. 2D-
12).
(5) Tap intermediate shaft out rear of case using
Arbor Tool J-25142 and plastic mallet (fig. 2D-13).
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