24-8. TRANSFER CASE ASSEMBLY REPAIR (CONT).
Rear housing assembly weighs 210 lbs (95 kg). Attach suitable lifting device before installation
to prevent possible injury to personnel.
Rear housing should be lowered until upper shift rod enters rod hole in housing. End of
rod should not cover opening for ball and spring in rear housing.
If necessary, turn front shaft to align splines on rear shaft.
Attach three lifting eyes and lifting device to rear housing (4).
Using lifting device, lower rear housing (4) on front housing (33) and align on upper shift rod (98) and
lower shift fork assembly (41).
Ball and spring must be compressed in hole to allow installation of shaft rod in transfer case
Install spring (35) and ball (34) in rear housing (4). Hold spring and ball with small push rod while
slowly lowering rear housing. When upper shift rod (98) contacts small push rod, pull small push rod out
of rear housing.
If necessary, use soft hammer to align
and seat rear housing on dowel pins.
Align two dowel pin holes (99) in flange of
rear housing (4) with two dowel pins (91) in
flange of front housing (33).
Lower rear housing (4) until fully seated on
front housing (33).
Remove lifting devices and three lifting eyes
from rear housing (4).
Adhesives, solvents, and sealing
compounds can burn easily, can
give off harmful vapors, and are
harmful to skin and clothing. To
avoid injury or death, keep away
from open fire and use in a well-
ventilated area. If adhesive,
solvent, or sealing compound
gets on skin or clothing, wash
immediately with soap and water.
Coat threads of 20 screws (32) with sealing
Install rear housing (4) to front housing (33) with
20 screws (32). Tighten to 88 lb-ft (119 N.m).