Overhaul

1. Remove transfer case from vehicle.
2. Remove transfer case side cover attaching bolts and cover. Clean gasket material from transfer case and cover.
3. Remove gear housing attaching bolts and gear housing subassembly.
4. Remove O-ring and shims. Wire shim stack together for assembly. Discard O-ring.
5. Place gear housing subassembly in a vise. Remove pinion nut, end yoke and washer.
6. Using a suitable hammer, tap drive gear, then remove from gear housing. Remove and discard collapsible spacer.
7. Remove inner bearing cone from drive gear. Install nut on end of drive gear to protect shaft.
8. Clean drive gear with suitable solvent. Install a new inner bearing cone assembly.
9. Mount drive gear housing in a suitable vise.
10. Remove drive gear housing oil seal.
11. Remove inner and outer drive gear bearing cups.
12. Remove gear housing from vise. Install new inner and outer drive bearing cups.
13. Lubricate and install new outer bearing cone.
14. Install a new collapsible spacer on drive gear stem.
15. Install drive gear into gear housing.
16. Install end yoke, washer and nut.
17. Tighten pinion nut in small increments until rotational effort is 15-32 inch lbs., with new bearings. Do not exceed this specification or a new collapsible spacer will have to be installed.
18. Eye protection must be worn when performing the following procedure:
a. Remove snap rings from vacuum servo shaft and shift fork. Remove shift motor assembly. Remove shift fork and fork clips.
b. Remove transfer case bearing cap attaching bolts and bearing cap.
c. Rotate bearing and remove two-piece snap ring from bearing.
d. Using a suitable screwdriver, remove inner snap ring which positions input gear to ball bearing. Slide bearing toward input gear and remove outer snap ring.
e. Slide input gear toward ball bearing until input gear and bearing can be lifted out of the transfer case.
f. Remove ball bearing from input gear.
g. Remove shift collar from clutch shaft.
h. Remove pinion nut and washer from clutch shaft. Using suitable tools, tap clutch shaft from transfer case.
i. Remove pinion gear, outer bearing and shims from transfer case. Wire shim(s) together and retain. Remove and discard clutch shaft collapsible spacer.
j. Remove clutch shaft inner bearing.
k. Place clutch shaft into a suitable vise. Remove clutch shaft needle bearing which centers input gear. Discard bearing.
19. Install a new clutch shaft needle bearing. Pack bearing with grease to maintain proper needle position.
20. Install clutch shaft inner bearing cone.
21. Place transfer case into a suitable working fixture. Install clutch shaft inner bearing cup remover T87P-7120-D or equivalent, and tighten.
22. Install tool No. T50T-100-A or equivalent, into a cup remover. Remove inner bearing cup. Remove outer bearing using the same procedure.
23. Wipe bearing boss clean. Install inner and outer bearing cups.
24. Install a new collapsible spacer onto clutch shaft.
25. Install clutch shaft into transfer case. Assemble original shim stack, removed earlier and pinion gear. Using a inch lb. torque wrench, measure torque until shaft rotational effort is 10-15 inch lbs., with new bearing installed.
26. Do not exceed specification or a new collapsible spacer will be required to obtain proper bearing preload.
27. Position shims and a new O-ring onto gear housing. Lubricate O-ring.
28. Install gear housing subassembly to transfer case. Torque four attaching bolts to 8-12 ft. lbs.
29. Check backlash between drive and pinion gear using a suitable dial indicator. Backlash should be .004-.006 inch.
30. Use white paint to obtain a gear contact tooth pattern. The contact pattern should be within the primary area of the drive gear tooth surface, avoiding any narrow or hard contact with outer perimeter of tooth (top to bottom, toe to heel). If a gross pattern error is detected with backlash set at .004-.006 inch, adjust drive pinion gear shim stack. Increasing shim stack thickness of the pinion gear should move the contact pattern on drive (pull) side of drive gear toward toe of tooth. Reducing shim stack thickness should move the contact pattern on drive (pull) side of drive gear tooth toward heel of tooth. When backlash and gear contact pattern are acceptable continue with assembly.
31. Install shift collar onto clutch shaft.
32. Side ball bearing onto input gear.
33. Install input gear into transfer case. Slide small end of input gear into clutch shaft.
34. Install snap ring onto outer end of shaft.
35. Slide bearing outboard and install snap ring onto inner end of input shaft. Ensure snap rings are completely seated in groove.
36. Install two-piece snap ring into groove for ball bearing and transfer case.
37. Install bearing cap and two attaching bolts. Torque bolts to 18-24 ft. lbs.
38. Inspect shift fork clips and replace, if necessary. Install shift fork onto clutch collar.
39. Install a new O-ring onto vacuum servo shaft. Lubricate O-ring with clean automatic transmission fluid.
40. Eye protection must be worn when performing the following procedure:
a. Install vacuum servo assembly into transfer case. Install snap ring. Ensure snap ring is completely seated in groove. Install shift fork snap rings.
b. Install transfer case side cover. Apply a bead of silicone rubber or equivalent onto cover surface of transfer case. Torque attaching bolts to 7-12 ft. lbs. The bead must be continuous and not go outside the cover holes.
c. Install transfer case and a new gasket to transaxle.
d. Install a new O-ring onto cup plug. Install cup plug into transfer case.