Disassembly and Assembly

Fig. 70 Exploded View Of Transfer Assembly:

DISASSEMBLY

1. Remove cover and cover gasket.
2. Remove extension housing assembly and transfer case subassembly.
3. Remove spacer, O-ring and transfer case adapter subassembly.

Fig. 71 Extension Housing Assembly:

SUBASSEMBLY SERVICE

EXTENSION HOUSING ASSEMBLY

1. Remove air breather.
2. Remove dust shield guard and oil seal from extension housing assembly.
3. Reverse procedure to assemble, noting the following:
a. Use oil seal installer MD998304 or equivalent when installing oil seal.
b. Prior to installing air breather, apply 3M Super Weather-strip No. 8001 or equivalent to air breather.

Fig. 72 Transfer Case Subassembly:

Fig. 73 Checking Turning Drive Torque Of Drive Bevel Gear Assembly:

TRANSFER CASE SUBASSEMBLY

1. Remove transfer cover.
2. Remove O-ring, spacer and outer race.
3. Remove drive bevel gear assembly, spacer and oil seal.
4. Reverse procedure to assemble, noting the following:
a. Use oil seal installer MD998323 or equivalent when installing oil seal.
b. Using preload socket tool No. MB990326 and side gear holding tool No. MB990900 or equivalents, check turning torque of the drive bevel gear assembly as shown. If turning torque is not within 1.23-1.81 lb-ft, adjust by installing new spacers. Select spacers of nearly same thickness on both sides.

Fig. 74 Transfer Case Adapter Subassembly:

Fig. 75 Taper Roller Bearing Installation:

Fig. 76 Checking Turning Drive Torque Of Driven Bevel Gear Assembly:

TRANSFER CASE ADAPTER SUBASSEMBLY

1. Unstake locknut and using special spanner tool No. MB991013 or equivalent, remove locknut.
2. Using a press, remove driven gear bevel assembly.
3. Remove taper roller bearing, spacer, collar and outer races.
4. Reverse procedure to assemble, noting the following:
a. When installing taper roller bearing, use installer cap tool No. MD998812, installer tube tool No. MD998814 and installer adapter tool No. MD998820 or equivalent as shown.
b. Torque locknut to 102-115 lb-ft, then stake locknut at two places.
c. Using wrench adapter tool No. MD998806 and suitable torque wrench or equivalent, check turning torque of the driven bevel gear assembly as shown. If turning torque is not within 0.72-1.23 lb-ft, adjust with adjusting spacer.

Fig. 77 Taper Roller Bearings Removal From Drive Bevel Gear Assembly:

Fig. 78 Taper Roller Bearings Installation On Drive Bevel Gear Assembly:

DRIVE BEVEL GEAR ASSEMBLY

1. Using bearing removal tool No. MD998801 or equivalent, remove taper roller bearings and drive bevel gear as shown.
2. Using installer cap tool No. MD998812 and installer adapter tool No. MD998827 or equivalent, install taper roller bearing above drive bevel gear.
3. Using bearing installation tool No. MD998350 or equivalent, install taper roller bearing at opposite end drive bevel gear.

Fig. 79 Taper Roller Bearings Removal From Driven Bevel Gear Assembly:

DRIVEN BEVEL GEAR ASSEMBLY

1. Using bearing removal tool No. MD998801 or equivalent, remove taper roller bearing from driven gear assembly.
2. Use collar to install taper roller bearing onto driven bevel gear.