Transfer Assembly Disassembly
- Remove gasket from mounting face of transfer assembly case. See Fig 1.
- Remove No. 2 intermediate differential side gear.
- Remove No. 1 case cover. Remove the 8 bolts. Using a brass bar and hammer, remove the No. 1 case cover. Remove bolt and breather oil deflector from the No. 1 case cover.
- Remove the 4 pins from the transfer case.
- Remove the 4 stud bolts from the transfer case.
- Install transfer case on appropriate holding fixture.
- Using plastic hammer, remove the dust deflector from the extension housing. Using appropriate puller and slide hammer, remove the oil seal from the extension housing.
- Remove 4 bolts securing extension housing. Using a plastic hammer, remove the extension housing.
- Using appropriate adapter and INCH lb. torque wrench, measure the driven pinion preload of the backlash between the driven pinion and ring gear. See Fig 2. Starting preload should be 7.8-11.5 INCH lbs. (.9-1.3 N.m).
- Continue to rotate torque wrench to measure total preload. Total preload should be 8.9-14.2 INCH lbs. (1.0-1.6 N.m).
- Using dial indicator, measure the ring gear backlash. See Fig 3. Backlash should be.004-.006" (.10-.15 mm).
- Remove center differential lock sleeve. Using snap ring pliers, remove the shaft snap ring. See Fig 1. Using appropriate puller and slide hammer, remove the center differential lock sleeve.
- Using a screwdriver or pick, remove the "O" ring from the center differential lock sleeve. See Fig 4.
- Remove oil seal. Using appropriate puller and slide hammer, remove the oil seal from the bearing retainer RH.
- Remove 7 bearing retainer RH bolts. Using a screwdriver and hammer, make clearance by hitting gap between the bearing retainer RH and transfer case.
- Using appropriate puller and slide hammer, remove the bearing retainer RH from the transfer case.
- Using a screwdriver, remove 2 "O" rings from the bearing retainer RH.
- Using the soft jaws, hold the bearing retainer RH in a vise. Using appropriate puller and slide hammer, remove the outer race, washer and oil seal from the bearing retainer RH.
- Using snap ring pliers, remove the snap ring. See Fig 1. Remove the side gear shaft holder bearing from the bearing retainer RH.
- Remove center differential control coupling assembly. Remove tapered roller bearing LH and RH. Using appropriate bearing puller, remove tapered roller bearing inner race LH and RH.
- Place center differential control coupling assembly on "V" blocks. See Fig 5. Using a dial indicator, check the ring gear runout. Maximum runout is.004" (.1 mm).
- Remove ring gear. Place matchmarks on both the ring gear and the center differential control coupling. Remove 12 bolts in crisscross pattern.
- Using a plastic hammer, remove the ring gear.
- Place center differential control coupling assembly back on "V" blocks. Using a dial indicator, check the coupling runout. Maximum runout is.003" (.07 mm).
- Remove driven pinion. Using appropriate punch and hammer, unstake the lock nut. Using driven pinion holding adapter, remove the lock nut. See Fig 6.
- Using a press, remove the driven pinion, rear bearing inner race and spacer.
- Using an appropriate bearing spreader and press, remove the front bearing inner race from the driven pinion.
- Remove bearing outer race LH. Using a brass bar and a hammer, remove the outer race and the washer.
- Remove front bearing outer race. Using a brass bar and a hammer, remove outer race and washer.
- Remove rear bearing outer race. Using a brass bar and a hammer, remove outer race.
NOTE:
Be careful not to damage the transfer case and No. 1 case cover.
NOTE:
Be careful not to damage the extension housing.
NOTE:
Ensure torque wrench has a fulcrum length of 6.3" (160 mm). Torque value is most accurate when torque wrench is parallel with adapter.
NOTE:
Be careful not to damage the center differential lock sleeve.
NOTE:
Be careful not to damage the bearing retainer RH.
NOTE:
Do not allow driven pinion to drop on floor.