Transfer Case Connecting Sleeve Seals, Replacing

Transfer Case Connecting Sleeve Seals, replacing

Special tools:
999 5777 Extractor 999 5777 Extractor
999 5575 PULLER CYLINDER USED WITH HYDRAULIC PUMP -5576 999 5575 Puller Cylinder Used With Hydraulic Pump -5576
999 5576 HYDRAULIC PUMP 999 5576 Hydraulic Pump
999 2615 Hydraulic pump 999 2615 Hydraulic Pump
999 7181 Drift 999 7181 Drift
999 7182 Drift 999 7182 Drift

Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Removal

Removing bevel gear
Remove the bevel gear according to: Bevel gear, replacing Bevel Gear Bevel gear, replacing, TF-80SC AWD Bevel Gear.





Action for worn splines in sleeve




Cut a - 40 mm piece of cardboard and use as protection to prevent grinding chips from ending up in the transmission. Apply a thick bead of grease or Vaseline on the seal in the sleeve. Press the piece of cardboard against the seal.




Grind a groove in the inside of the sleeve to enable the expander999 5777 Extractor 999 5777 Extractor to get a hold.
The sleeve can also be heated with a hot-air gun or induction heater.




Install: 999 5777 Extractor 999 5777 Extractor and 999 5777 Extractor 999 5777 Extractor to 999 5575 PULLER CYLINDER USED WITH HYDRAULIC PUMP -5576 999 5575 Puller Cylinder Used With Hydraulic Pump -5576.
999 5575 PULLER CYLINDER USED WITH HYDRAULIC PUMP -5576 999 5575 Puller Cylinder Used With Hydraulic Pump -5576 used with: 999 5576 HYDRAULIC PUMP 999 5576 Hydraulic Pump (foot operated).
Alternatively: 999 2615 Hydraulic pump 999 2615 Hydraulic Pump , which consists of puller cylinder and a compressed air powered hydraulic pump.





Note! Place a container underneath the transmission.








Installation




Heat the sleeve in an oven to 100 - 120° C and place in: 999 7181 Drift 999 7181 Drift. Install on the transmission and tap in the sleeve until it reaches the differential.

Warning! Use protective gloves when handling the heated sleeve.

Warning! Use ear protectors

Cool the sleeve using compressed air.




Install: 999 7182 Drift 999 7182 Drift.
Carefully install both sealing rings.




Use: 999 7181 Drift 999 7181 Drift and tap in both the seals.





Installing the bevel gear
Fit the bevel gear according to: Bevel gear, replacing Bevel Gear Bevel gear, replacing, TF-80SC AWD Bevel Gear

Checking the oil level
Check the fluid level in the transmission. See: Oil level, checking, TF-80SC AWD Checking Oil Level.