Transfer Case Service - Out-Of-Vehicle; Transfer Case Removal (Quadra-Trac); Transfer Case Installation (Quadra-Trac); Drive Sprocket Oil Seal Replacement - Jeep 1979 CJ-5 Technical & Service Manual

2B-32
T R A N S F E R C A S E
T R A N S F E R C A S E SERf ICE—-OUT-OF-VEHICLE
Truster Case
Removal
Transfer case removal Is not required except when the
front output shaft, front annular bearing, transmission
output shaft seals or the transfer case front cover re-
quire service. The drive chain, drive sprocket, differen-
tial, diaphragm control, needle bearing, thrust washer,
or rear output shaft are serviced in the vehicle by re-
moving the transfer case rear cover. Refer to Rear
Cover-Sprockets-Drive Chain Removal under Transfer
Case Service—In-Vehicle.
(1) Raise vehicle.
(2) On Cherokee, Wagoneer and Truck models
equipped with low range reduction unit, remove reduc-
tion unit. Refer to Reduction Unit Removal.
(3) Mark transfer case front and rear output shaft
yokes and propeller shafts for assembly alignment
reference.
(4) Mark Emergency Drive control diaphragm vac-
uum hoses for assembly reference and disconnect hoses.
(5) Disconnect Emergency Drive indicator switch
wire.
(6) Disconnect speedometer cable.
(7) On CJ-7 models, place support stand under
transmission and remove rear crossmember.
(8) Mark transfer case front and rear output shaft
yokes and propeller shafts for assembly alignment
reference.
(9) Disconnect front and rear propeller shafts at
transfer case yokes. Secure shafts to frame rails with
wire.
(10) Disconnect parking brake cable guide from pivot
located on right frame rail.
(11) Remove bolts attaching exhaust pipe support
bracket to transfer case.
(12) Remove two transfer case-to-transmission bolts
which enter from front side of vehicle.
(13) Remove two transfer case-to-transmission bolts
which enter from rear of vehicle and install 7/16-14 by 5-
inch (12.70 cm) long guide pin in each hole.
NOTE: If the guide pins are difficult to install, the
transfer case attaching bolts may have created burrs on
the bolt hole edges. Remove these burrs using a penknife
or small file.
(14) Move transfer case assembly rearward until free
of transmission output shaft and guide pins and remove
assembly.
(15) Remove all gasket material from rear of
transmission.
Transfer Case Installation
(1) Apply Permatex No. 3, or equivalent sealer, to
both sides of transfer case-to-transmission gasket and
position gasket on transmission.
(2) Install guide pins in upper and lower threaded
holes in transmission adapter.
(3) Align and install transfer case assembly on
transmission. Be sure drive hub splines are aligned with
transmission output shaft. Align splines by rotating
transfer case rear output shaft yoke if necessary.
NOTE: Do not install any transfer case attaching bolts
until the transfer case is completely seated against the
transmission.
(4) Install transfer case attaching bolts. Tighten
bolts to 40 foot-pounds (54 N«m) torque.
(5) Remove guide pins and install remaining trans-
fer case attaching bolts. Tighten bolts to 40 foot-pounds
(54 N«m) torque.
(6) Attach exhaust pipe support bracket to transfer
case.
(7) Align and connect propeller shafts.
(8) Connect emergency drive indicator switch wire.
(9) Connect emergency drive control diaphragm
vacuum hoses. Be sure to connect hoses according to
alignment marks made at disassembly.
(10) Connect parking brake cable guide to pivot
bracket on right side frame rail.
(11) On CJ-7 models, install rear crossmember and
remove transmission support stand.
(12) On Cherokee, Wagoneer and Truck models, in-
stall low range reduction unit, if equipped.
(13) Fill transfer case and reduction unit with speci-
fied lubricant. Refer to Lubrication.
(14) Lower vehicle.
Drive Sprocket Oil Seal Replacement
NOTE: Although the drive sprocket oil seals can be
replaced without disassembling the transfer case, the
transfer case must be removed from the vehicle in order
to replace these seals.
(1) Remove seals using J-type puller or smooth-
ended pry bar. Do not damage case bore during seal
removal.
(2) Insert replacement rear seal in case bore with
seal lip facing interior of transfer case (fig. 2D-50).
(3) Seat rear seal using Driver Tool J-25213 and
Sleeve J-25213-1 (fig. 2D-51). Install seal until shoulder
of sleeve tool contacts case front surface.
(4) Remove driver and sleeve tools.
(5) Insert replacement front seal in case bore with
seal lip facing away from transfer case and toward open
end of case bore (fig. 2D-50).
(6) Seat front seal using Driver Tool J-25213 and
Sleeve J-25213-1. Install seal until tool shoulder contacts
case front surface (fig. 2D-51).