'Jeep'
UNIVERSAL SERIES SERVICE
MANUAL
ft
TRANSFER CASE
Contents
SUBJECT
PAR.
GENERAL
. . .K-1
TRANSFER CASE REMOVAL
K-2
TRANSFER CASE DISASSEMBLY
K-3
Front
Bearing Cap K-4
Rear
Bearing Cap K-5
TRANSFER CASE REASSEMBLY.
. .K-6
TRANSFER CASE INSTALLATION
K-7
TRANSFER CASE LINKAGE
ADJUSTMENT
K-8
SERVICE
DIAGNOSIS
K-9
SPECIFICATIONS
.K-10
K-1. GENERAL
All
4-wheel-drive models are equipped with a
transfer
case to connect the power to the front
axle.
It is essentially a
two-speed
transmission
located at the
rear
of the standard transmission
and
provides a low and direct gear.
The
transfer case gears are controlled by the
driver
through
one shift lever.
Early
'Jeep'
Universal
Models with the F4-134
Hurricane
engine
are equipped with two transfer case shift control levers.
a.
On vehicles equipped with one transfer case
shift
lever, the transfer case shift lever has four
positions: 2WD
High,
4WD
High,
Neutral, and
4WD
low. The forward position of the lever 2WD
High
allows the
rear
wheels only to drive. The
first
rear
position (4WD High)
engages
the 4- wheel drive and provides high range 4-wheel drive.
The
second
rear
position (Neutral)
disengages
all power to the wheels and is used for stationary
power take-off operations. The last
rear
position
(4WD
Low) provides low range 4-wheel drive.
b.
On vehicles equipped with two transfer case
shift
levers, the transfer case front axle drive lever (left hand lever)
gives
a choice of 2-wheel or 4-
wheel drive. In the forward (out) position the
vehicle is in 2-wheel drive. Move the lever to the
rear
(in) position for 4-wheel drive operation.
The
4-wheel-drive
auxiliary-range
shift lever (right
hand
lever) has three positions; low, neutral, and
high.
The forward position (low)
gives
low-range
4-wheel drive. The center position (neutral) dis
engages
all power to the wheels and is used for
stationary
power take-off operations. A built-in in
terlock
prevents shifting into low range, 2-wheel
drive.
This
feature protects the
rear
axle from over
load.
K-2.
Removal of
Transfer
Case
The
transfer case may be removed from the vehicle
without removing the transmission. Where both
transmission
and transfer case are to be removed
together,
refer to Section J. To remove only the
transfer
case from the vehicle, proceed as follows:
a.
Drain
transmission
and transfer case and replace
drain
plugs.
b.
Disconnect the brake cable.
c.
Disconnect front and
rear
propeller shafts at
the transfer case. See "Propeller Shafts and
Uni
versal
Joints."
d.
Disconnect
speedometer
cable at transfer case. e. Disconnect the transfer case shift levers. On
vehicles equipped with two shift levers
loosen
set screw and remove pivot pin. Use a screw
driver
to pry shift lever springs away from shift levers.
Lift
levers from transfer case. On models equipped
with
a single shift lever remove pivot pin cotter
key,
and the adjusting rod attaching nut to remove
shift
lever. See Fig. K-4.
f. Remove cover plate on
rear
face of transfer case.
Remove
cotter key, nut and washer from trans
mission
main shaft.
g. If possible, at this point remove the transfer case main drive gear from the transmission main
shaft.
If not possible, see
step
j below.
h.
Remove transfer case torque reaction support
bracket
bolt and nut.
i.
Remove transmission to transfer case bolts.
j.
Remove transfer case. If the transfer case main
drive
gear has not been removed in
step
g above,
proceed as follows:
Brace
the end of the trans
mission
main shaft so that it cannot
move
in the
transmission,
pull
the transfer case to the
rear
to 267
