Installation

TRANSFER CASE ADAPTER SUB ASSEMBLY INSTALLATION

Apply a light and uniform coat of machine blue or red lead to the driven bevel gear teeth (both sides) using a brush.




SPACER INSTALLATION

Install the spacer that has been used.




TRANSFER CASE SUB ASSEMBLY INSTALLATION

1. With the matching marks in alignment, install the transfer case adapter sub assembly to the transfer case sub assembly.




2. Tighten the transfer case adapter sub assembly to the transfer case sub assembly to specified torque.

Transfer case adapter mounting bolt: 39 Nm (28 ft.lbs.)




3. Use the special tool to turn the drive bevel gear shaft (one turn in normal direction, one turn in reverse direction).

NOTE: Do not give the drive bevel gear shaft more than one turn in either direction as this causes unclear tooth contact pattern.




4. Check that the driven bevel gear and transfer case matching marks are in alignment.




5. Check if the drive bevel gear tooth contact is normal.

NOTE: Refer to the TOOTH CONTACT ADJUSTMENT PROCEDURES (below) for the standard tooth contact.




6. Check if the drive bevel gear and driven bevel backlash is as specified.

Standard value: Bevel gear set backlash 0.08-0.13 (0.0031-0.0051 in.)




EXTENSION HOUSING INSTALLATION

Apply sealant to the adapter flange surface and install the extension housing.

Specified sealant: Mitsubishi genuine sealant Part No. MD997140 or equivalent

NOTE: Squeeze out sealant from the tube uniformly and continuously in adequate amount.




SEALANT TO COVER GASKET APPLICATION

Specified sealant: MOPAR Part No.4318034 or Three Bond Part No. 1141E.




TOOTH CONTACT ADJUSTING PROCEDURES

1. Standard tooth contact pattern

A. Small end side
B. Drive side tooth face (Side on which force acts when running forward)
C. Big end side D Coast side tooth face (Side on which force acts when reversing)




2. Tooth contact pattern produced when drive bevel gear height is too large

Cause: The driven bevel is too close to the drive bevel gear.




Remedy: Use thicker bevel gear mount adjusting spacer to separate the driven bevel gear more from the drive bevel gear.




3. Tooth contact pattern is produced when driven bevel gear height is too small.

Cause: The driven bevel gear is too separated from the drive bevel gear.




Remedy: Use thinner driven bevel gear mount adjusting spacer to bring the driven bevel gear closer to the drive bevel gear.




NOTE:

1. If correct tooth contact cannot be obtained even by change of the driven bevel gear mount adjusting spacer, increase or decrease the drive bevel gear preload adjusting spacer and the drive bevel gear mount adjusting spacer as described below and then adjust tooth contact again.

- When the driven bevel gear height is too small even if the thinnest driven bevel gear mount adjusting spacer 0.13 mm (.0051 in.) is used:

Replace the drive bevel gear mount adjusting spacer that is in use with one that is one rank thicker and replace the drive bevel preload adjusting spacer that is in use with one that is one rank thinner.

- When the driven bevel gear height is too large even if the thickest driven bevel gear mount adjusting spacer 0.52 mm (.0205 in.) is used:

Replace the drive bevel gear mount adjusting spacer that is in use with one that is one rank thinner and replace the drive bevel gear preload adjusting spacer that is in use with one that is one rank thicker.

Repeat above steps until the tooth contact pattern equal or close to the standard pattern is obtained.

2. If the tooth contact pattern cannot be adjusted close to the standard pattern by above adjustment, replace the drive bevel gear and driven bevel gear as a set and readjust the tooth contact.