Transfer Case Service - In-Vehicle - Jeep 1979 CJ-5 Technical & Service Manual

C O L L A R
PLATE
C O L L A R
P L A T E H U B
J42387
Fig 2041 Ring Gear Assembly
NEEDLE
BEARING
(2)
R I N G
GEAR
C O L L A R
J42389
Fig. 2042 i i i g Gear Installed on Miction Collar Hub
(28) Support assembly with one hand and insert
main shaft into bore of shift collar hub with other hand.
Be sure main shaft and sun gear are fully seated.
(29) Install main shaft and sun gear through open
end of ring gear.
(30) Hold assembled parts firmly together. Raise as-
sembly and position assembly on socket (mounted in
vise) used to s u p p p o r t r e d u c t i o n u n i t d u r i n g
disassembly.
(31) Install needle bearing and direct drive sleeve on
main shaft.
(32) Align splines on assembled parts and install
housing (fig. 2D-29). Be sure housing is seated firmly
against direct drive sleeve.
(33) Install rear spacer and snap ring. Be sure snap
ring is fully seated in snap ring groove.
NOTE: The snap ring is a select-fit component and is
available in the following thickness ranges: 0.089 to
0.091 inch (2.26 to 2.31 mm), 0.092 to 0.09k inch (2.33 to
2.38 mm), 0.095 to 0.097 inch (241 to 246 mm), 0.099 to
0.101 inch (2.51 to 2.56 mm), and 0.103 to 0.105 inch (2.61
to 2.66 mm). Install the thickest snap ring possible to
provide
0.004-0.009
inch (0.10-0.22 mm) spacer
clearance.
(34) Install power takeoff cover and gasket. Tighten
cover attaching bolts to 20 foot-pounds (27 N*m) torque.
(35) Remove assembled unit from support socket and
install pinion cage.
(36) Remove socket from vise.
TRANSFER CASE SERVICE—IN-VEHIGLE
Front/Rear Output Shaft Seal Replacement
(1) Raise vehicle.
(2) If front output shaft seal is to be replaced, place
support stand under transmission and remove rear
crossmember.
(3) Mark propeller shaft and transfer case yoke for
assembly alignment reference.
(4) Disconnect propeller shaft at transfer case yoke.
Secure shaft to frame rail using wire.
(5) Remove yoke retaining nut using socket, socket
handle, and tool J-8614-01 (fig. 2D-8).
(6) Remove yoke using tools J-8614-01, J-8614-02,
and J-8614-03 (fig. 2D-9).
(7) Remove shaft seal using tool J-25180.
(8) Install replacement seal using tool J-25160.
(9) Install yoke, washer, and replacement retaining
nut on shaft.
(10) Install tool J-8614-01 on yoke to prevent yoke
from turning and tighten yoke retaining nut to 120 foot-
pounds (163 N*m) torque.
(11) Connect propeller shaft to yoke. Index yoke to
shaft using alignment marks made at disassembly.
(12) If front seal was replaced, install rear cross-
member and remove transmission support stand.
(13) Lower vehicle.
Rear Cover-Sprockets-Drive Chain Removal
(1) Raise vehicle.
(2) Remove reduction unit, if equipped. Refer to
Reduction Unit Removal.
NOTE: The reduction unit cage will remain in the
transfer case when the reduction unit is removed.
(3) Remove transfer case drain plug and drain
lubricant.
(4) Mark rear propeller shaft and yoke for assembly
alignment reference.
(5) Disconnect rear propeller shaft at transfer case
yoke.