Transfer Shaft Repair

DISASSEMBLY

Rear Cover Bolts:

Remove Or Install Rear Cover:

Remove Transfer Shaft Gear Retaining Nut:

Transfer Shaft Gear Nut And Washer:

Remove Transfer Shaft Gear:

Transfer Shaft Gear And (Select) Shim:

Using Tool L-4406-1 With Adapter L-4406-3, Remove Transfer Shaft Gear Bearing Cone:

Install Transfer Shaft Gear Bearing Cone:

Governor Support Retainer:

Remove Governor Support Retainer Bearing Cup:

Install Governor Support Retainer Bearing Cup:

Low/Reverse Band Anchor Pin:

Governor Assembly:

Transfer Shaft Bearing Snap Ring:

Remove Transfer Shaft And Bearing Retainer Assembly:

Remove Or Install Transfer Shaft And Bearing Retainer Assembly Using Tool L-4512:

Transfer Shaft And Bearing Retainer:

Remove Transfer Shaft Bearing Cone:

NOTE: Remove old sealant before applying new sealant. Use MOPAR RTV sealant, or equivalent, when installing cover.

Stirrup And Strap Removal

NOTE: A stirrup and retaining strap is attached to the transfer gear. The stirrup prevents the transfer gear retaining nut from turning and backing off the transfer shaft. The strap is used to hold the stirrup to the transfer gear and prevent the stirrup retaining bolts from backing out.

1. Using a punch, bend tabs on strap flat against transfer gear.
2. Remove bolts holding retaining strap to stirrup.
3. Remove strap from transfer gear and stirrup.
4. Remove stirrup from transfer gear.

NOTE: Remove or install both governor valves and governor body.

DETERMINING SHIM THICKNESS
Shim thickness need be determined only if any of the following parts are replaced:
- Transaxle case
- Transfer shaft
- Transfer shaft gear
- Transfer shaft bearings
- Governor support retainer
- Transfer shaft bearing retainer
- Retainer snap ring
- Governor support

Refer to Bearing Adjustment Procedure to determine proper shim thickness.

Install Transfer Shaft Bearing Cone:

Remove Transfer Shaft Bearing Cup:

Install Transfer Shaft Bearing Cup:

Tighten Transfer Shaft Gear Retaining Nut To 271 Nm (200 Ft. Lbs.):

Checking Transfer Shaft End Play:

ASSEMBLY
To install transfer shaft, reverse the above procedure.

Stirrup And Strap Installation
Once bearing shim selection has been adjusted, install stirrup and strap assembly onto transfer gear.

NOTE: Once the stirrup assembly is positioned onto the transfer gear, it is necessary to "clock" the stirrup against the flats of the transfer gear retaining nut.

1. Position the stirrup on the transfer gear.
2. Position strap.
3. Install retaining bolts into transfer gear. Finger-tighten bolts.
4. Turn stirrup clockwise against the flats of the transfer gear retaining nut.
5. Tighten retaining bolts to 23 Nm (200 inch lbs.).
6. Bend tabs of strap up against "flats" of retaining bolts.