Required Tools | |||
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Tool | Part Number | Part Description | Qty |
A | 1P-0520 | Driver Gp | 1 |
C | 138-7573 | Link Bracket | 2 |
K | - | Loctite 592 | - |
L | 1P-0808 | Multipurpose Lithium Grease | - |
M | - | Loctite C5-A | - |
Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected at all times.
NOTICE |
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Failure to properly assemble parts or failure to follow established procedures can lead to damage of the parts and assembly. To avoid damage to parts, always identify and mark the parts so that they can be installed in the same location. Ensure that gear surfaces align. Never force parts during assembly. |
- Lower the temperature of bearing cups (44) and (45).
- Install the bearing cups to the transfer case.
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Illustration 2 g01061260 - Raise the temperature of two bearing cones (46). Install bearing cones (46) to gear (43).
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Illustration 3 g01061676 - Attach a suitable lifting device to gear (43). The weight of gear (43) is approximately
29 kg (64 lb) . - Install gear (43).
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Illustration 4 g01061680 - Raise the temperature of bearing cones (42).
- Install the bearing cones on gear (41).
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Illustration 5 g01061697 - Attach a suitable lifting device to gear (41). The weight of gear (41) is approximately
39 kg (86 lb) . - Install gear (41).
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Illustration 6 g01061252 Show/hide tableIllustration 7 g01117990 - Apply Tooling (M) to the threads of speed sensors (39) and (40). Install speed sensors (39) and (40).
- Set the clearance (X) between the sensors and the gear to
0.71 mm (0.028 inch) . Tighten the lock nut on each sensor to a torque of25 ± 5 N·m (18 ± 4 lb ft) .Show/hide tableIllustration 8 g01061698 - Apply Tooling (K) using a
3 ± 0.5 mm (0.12 ± 0.012 inch) continuous bead to the mating surface of the transfer case. - Install Tooling (C) and a suitable lifting device to gear case cover (38). The weight of gear case cover (38) is approximately
45 kg (100 lb) . - Install gear case cover (38).
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Illustration 9 g01061242 - Install eight bolts (37) that hold the cover to the transfer case. Tighten eight bolts (37) to a torque of
135 ± 20 N·m (100.0 ± 15.0 lb ft) .Show/hide tableIllustration 10 g01061241 - Install drain assembly (36) and bolts (35).
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Illustration 11 g01062025 - Lower the temperature of the bearing cup . Install the bearing cup to bearing cage (32).
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Illustration 12 g01062028 - Install O-ring seal (33) on the bearing cage (32). Install cover (30).
- Install the nuts that hold the cover in place.
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Illustration 13 g01062027 - Lower the temperature of the bearing cup. Install the bearing cup to bearing cage (28).
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Illustration 14 g01062378 - Install bearing cage (32) and bearing cage (28) in the transfer case. DO NOT install the O-ring seal or the shims at this time. Install two bolts and the washers at a 180° interval in each bearing cage (28) and (32), and tighten the bolts to a torque of
20.3 N·m (180 lb in) . - Rotate gears (41) and (43) about 30° for three or four times. Tighten the bolts in each bearing cage (28) and (32) to a torque of
40.7 N·m (360 lb in) . - Rotate gears (41) and (43) about 30° for three or four times. Without moving the gears, back off the bolts in each bearing cage (28) and (32). Tighten the bolts again until the bolts are finger tight. Tighten the bolts to a torque of
20.3 N·m (180 lb in) . - Rotate gears (41) and (43) about 30° for three or four times. Tighten the bolts in each bearing cage (28) and (32) to a torque of
20.3 N·m (180 lb in) . Continue to tighten the bolts in each bearing cage (28) and (32) until the bolts do not move at a torque of20.3 N·m (180 lb in) . - Measure the gaps between the housing and bearing cages (28) and (32). Take two measurements for each bearing cage, and measure the gaps at each bolt. Measure the gap between the bearing cage and the housing from the center of the bolt to the outside diameter of the flange.
- Add the two measurements for each bearing cage. Divide the sum for each bearing cage by two to give the average gap for each bearing cage.
Note: Step 27 is used for the gap at bearing cage (28).
- Add
0.41 mm (0.016 inch) to the average gap measurement in order to determine the thickness of the shims.Note: Step 28 is used for the gap at bearing cage (32).
- Add
0.46 mm (0.018 inch) to the average gap measurement in order to determine the thickness of the shims. - Assemble the correct shim pack in order to match the thickness in Step 27 or Step 28. Use a micrometer, and verify that the shim pack thickness is the same as in Step 27 or Step 28.
- Remove bearing cages (28) and (32). Install the shim packs, the O-ring seals, and the bearing cages. Install the bolts in bearing cages (28) and (32). Tighten the bolts to a torque of
135 ± 20 N·m (100.0 ± 15.0 lb ft) .Show/hide tableIllustration 15 g01062384 - Install O-ring seal (26) to cover (25).
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Illustration 16 g01060512 - Install cover (25) and nine bolts (24).
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Illustration 17 g01062385 - Raise the temperature of bearing (23). Install the bearing on the shaft.
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Illustration 18 g01062386 Show/hide tableIllustration 19 g01060510 - Lower the temperature of two bearing cups (22). Install the bearing cups and the bearing cones in bearing cage (17).
- Install retainer (21) and six bolts (20). The part number on the retainer should be visible.
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Illustration 20 g01062388 - Use Tooling (A) to install the lip seal in bearing cage (17).
Note: The seal must contact the counterbore in the bearing cage. The lip of the seal must face toward the inside of the bearing cage.
Show/hide tableIllustration 21 g00678346 - Place the bearing cage, the spacer, and the gear in a suitable press. Install the shaft assembly through the gear, the spacer, and the bearing cage with the press.
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Illustration 22 g01060501 Show/hide tableIllustration 23 g01060491 - Install Tooling (C) and a suitable lifting device to bearing cage assembly (17). The weight of bearing cage assembly (17) is approximately
95 kg (210 lb) . - Install O-ring seal (18). Lightly lubricate the bore with the lubricant that is being sealed.
- Install bearing cage assembly (17) to the transfer case.
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Illustration 24 g01060476 - Install bolts (16). Tighten bolts (16) to a torque of
135 ± 20 N·m (100 ± 15 lb ft) .Show/hide tableIllustration 25 g01060144 - Install yoke (15) and O-ring seal (14).
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Illustration 26 g01060143 - Install bolt (12) and retainer (13). Tighten bolt (12) to a torque of
480 ± 52 N·m (355 ± 40 lb ft) . - Turn the transfer case. The weight of the transfer case is approximately
520 kg (1150 lb) .Show/hide tableIllustration 27 g01062389 - Lower the temperature of the bearing cup. Install the bearing cup to bearing cage (9).
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Illustration 28 g01062390 - Install O-ring seal (11) to bearing cage (9).
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Illustration 29 g00514020 - Use Tooling (A) to install the lip seal in the bearing cage. The seal must contact the counterbore in the bearing cage. The lip of the seal must face toward the inside of the bearing cage.
- Apply Tooling (L) to the lip of the seal and on the O-ring seal.
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Illustration 30 g01060139 - Install bearing cage (9) to the transfer case.
- Install bolts (8). Tighten bolts (8) to a torque of
55 ± 10 N·m (40 ± 7 lb ft) .Show/hide tableIllustration 31 g01060138 - Install yoke (7) and O-ring seal (6).
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Illustration 32 g01060137 - Install retainer (5) and bolt (4). Tighten bolt (4) to a torque of
480 ± 52 N·m (355 ± 40 lb ft) .Show/hide tableIllustration 33 g00673112 - Install O-ring seal (3).
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Illustration 34 g01060134 - Install adapter (1) and four bolts (2).
Illustration 1 | g01061668 |
End By:
- Connect the output transfer gears. Refer to Disassembly and Assembly, "Transmission to Output Transfer Gears - Connect".