Transfer Case

Transfer Case 1 – nut; 2 – output flange; 3 – oil seal; 4 – bearing; 5 – bearing outer race; 6 – plug; 7 – transfer case housing; 8, 9 – adjusting shims; 10 – bearing outer race; 11 – bearing; 12 – driven gear; 13 – oil seal; 14 – transfer case housing; 15 – bolt; 16 – washer; 17 – adjusting shim; 18 – bearing outer race; 19 – bearing; 20 – output shaft; 21 – gear shaft; 22 – drive gear; 23 – bearing; 24 – bearing outer race; 25 – bushing; 26 – oil seal; 27 – nut with ring; 28 – oil seal; 29 – locking plate; 30 – bolt; 31 – spacer ring; 32 – washer; 33 – spring; 34 – axle shaft flange; 35 – washer; 36 – retaining ring; 37 – cap

Disassembly PROCEDURE 1. Remove the transfer case.

2. Mark the relative position of output flange 2 and transfer case housing 7. 3. Unscrew nut 1. 4. Remove output flange 2. 5. Remove protective cap 37. 6. Remove retaining ring 36 and washer 35. 7. Remove axle shaft flange 34 with spring 33, washer 32 and spacer ring 31. 8. Remove output shaft 20 from the other side. 9. Unscrew bolts 30 and remove locking plate 29. 10. Unscrew nut with ring 27.

11. Unscrew bolts 15.

12. Separate the transfer case housing.

13. Remove driven gear 12 and drive gear 22. Assembly PROCEDURE Assemble the transfer case in the reverse order of disassembly. Before joining the housing halves, apply sealant to their mating surfaces. Tighten housing bolts 15 to torque 25 N·m.