1993 DODGE TRUCK transmission oil

21
- 322
TRANSMISSION
OVERHAUL-46RH

•

J932M33

Fig.
155
Checking
Alignment
Of Overdrive Planetary
Gear
And Overrunning
Clutch
Splines—46RH
(44) Carefully withdraw alignment tool from over­
drive unit.
(45) Lubricate intermediate shaft splines and
bushing surfaces with transmission fluid or petro­ leum jelly.
(46) Install overdrive unit. Be sure governor tubes
are aligned with feed holes in piston retainer boss.
Intermediate shaft is snug fit in overdrive planetary
gear and overrunning clutch. If overdrive unit will
not seat fully, rotate overdrive output shaft slightly
to align splines and try again.
(47) Apply 1-2 drops of Mopar thread adhesive (or
Loctite 242) to overdrive unit attaching bolts. Then
install and tighten bolts to 34 N» (25 ft. lbs.) torque.
(48) Install accumulator inner spring, piston and
outer spring (Fig. 156).

ACCUMULATOR
OUTER

Fig.
156 Installing
Accumulator
Piston
And
Springs
(49) Verify that park/neutral position switch has
not been installed in case. Valve body can not be in­ stalled if switch is in position.
(50) Install valve body as follows: (a) Start park rod into park pawl. If rod will not
slide past park pawl, pawl is engaged in park gear.
Rotate overdrive output shaft with socket to free
pawl and allow rod to engage. (b) Align and seat valve body on case. Be sure
manual lever shaft and overdrive connector are
fully seated in case.
(c) Install and start all valve body attaching
bolts by hand. Then tighten bolts evenly, in a di­ agonal pattern to 12 Nnn (105 in. lbs.) torque. Do
not overtighten valve body bolts. This could result in distortion and cross leakage after in­ stallation..
(51) Install new filter on valve body. Tighten filter
screws to 4 Nnn (35 in. lbs.).
(52) Install seal on park/neutral position switch
(Fig. 157). Then install and tighten switch to 34 Nnn
(25 ft. lbs.).
Fig.
157 Park/Neutral Position
Switch
Seal
Position
(53) Adjust front and rear bands as follows:
(a) Loosen locknut on each band adjusting screw
4-5 turns.
(b) Tighten both adjusting screws to 8 Nnn (72
in. lbs.).
(c) Back off front band adjusting screw 2-1/2

turns.

(d) Back off rear band adjusting screw 2 turns.
(e) Hold each adjusting screw in position and
tighten locknuts to 34 Nnn (25 ft. lbs.) torque.
(54) Install magnet in oil pan. Magnet goes on
small protrusion at corner of pan.
(55) Position new oil pan gasket on case and in­
stall oil pan. Tighten pan bolts to 17 Nnn (13 ft. lbs.).
(56) Install new valve body manual shaft seal in
case (Fig. 158). Lubricate seal lip and manual shaft
with petroleum jelly. Start seal over shaft and into
case.
Seat seal with 15/16 inch, deep well socket.
(57) Install throttle valve and shift selector levers
on valve body manual lever shaft. (58) Cap or cover transmission openings (cooler
line fittings, filler tube bore, etc.) to prevent dirt en­
try.
(59) Install torque converter. Use C-clamp or metal
strap to hold converter in place for installation. (60) Mount transmission on jack for installation in
vehicle.
(61) Apply dielectric grease to terminal pins of so­
lenoid case connector and neutral switch.

•

OVERDRIVE
UNIT
OVERHAUL—42RH/46RH
21 - 333 Check the machined surfaces on the output shaft.
These surfaces should clean and smooth. Very minor nicks or scratches can be smoothed with crocus cloth.
Replace the shaft if worn, scored or damaged in any
way.
Check condition of the governor components. Re­
place the governor drive seal rings if damaged. Be sure the drive ring grooves are in good condition. Check operation of the governor valve, weights and
shaft. The valves and weights should slide freely in
the governor body (Fig. 36).
There are two governor component changes in
current overdrive unit units. The first involves
the governor valve which is now made of alumi­
num. The second involves the output shaft which has a spotface for governor valve end
clearance. The new aluminum valve is not inter­
changeable. It must only be used with an output
shaft that has the spotface for valve end clear­ ance.
Inspect the governor support and the two oil pres­
sure tubes (Fig. 36). The tubes are an integral
part of the support. Do not attempt to remove
them.
The oil tubes must not be pinched, kinked, col­
lapsed, or distorted. Blow them out with compressed
air to be sure they are clear. The tubes are designed
to be a slip fit in the piston retainer boss. Do not modify the tube ends in an effort to make them fit
tighter.
Replace the governor support and the oil tubes as
an assembly if either component is damaged.
Check condition of the governor valve and weight
snap rings. Replace any snap ring that appears bent
or distorted. Replace any snap ring if its condition is
doubtful.
Inspect the output shaft bushings (Fig. 37). The
small bushing is the intermediate shaft pilot bush­
ing. The large bushing is the overrunning clutch hub
bushing. Replace either bushing if scored, pitted, cracked, or worn.
The bushings can be removed with "blind hole
puller tools" such as Snap-On set CG40CB for small
bushings and set CG46 for large bushings. New
bushings can be installed with tools from an all pur­
pose installer kit such as the Snap-On A257 bushing driver set.

OVERDRIVE
GEARTRAIN
ASSEMBLY
(1) Lubricate geartrain components with Mopar
ATF Plus or Dexron II™ transmission fluid. (2) Soak direct and overdrive clutch discs in trans­
mission fluid before installation. (3) Install new pilot bushing and clutch hub bush­
ing in output shaft if necessary (Fig. 37). Lubricate
new (or old) bushings with petroleum jelly. (4) Install front bearing and bearing snap ring on
output shaft (Fig. 38)
Fig.
37 Output Shaft
Bushing
Location
(5) Align and install annulus gear on output shaft
(Fig. 38). (6) Install annulus snap ring (Fig. 38).

Fig.
38 Installing
Annulus
Gear And
Snap Ring

(7) Align and install clutch drum on annulus gear
(Fig. 39). Be sure drum is engaged in annulus gear

lugs.

(8) Install clutch drum outer retaining ring (Fig.

31).
(9) Slide clutch drum forward and install inner re­
taining ring (Fig. 39).
(10) Install overrunning clutch on hub (Fig. 40).
Note that clutch only fits one way. Shoulder on
clutch should seat in small recess at edge of

hub.

(11) Install thrust bearing on overrunning clutch
hub (Fig. 41). Use generous amount of petroleum
jelly to hold bearing in place for installation. Bear­ ing fits one way only. Be sure bearing is seated squarely against hub. Reinstall bearing if it does
not seat squarely.

•

NP20I
TRANSFER CASE
21 - 34i (5) Verify that transfer case range lever is in Neu­

tral.
(6) Move shift lever bracket forward and retighten
bracket bolts (Fig. 3). Shift rod should not bind in shift lever and range lever. Rod should be slip-fit
both levers. (7) Shift transfer case into 4H range. Shift rod
should now be tension-fit in each lever. Shift lever
should be in 4H detent in gate and range lever should be fully into 4H position.
(8) Shift transfer case into 2H and 4L ranges to
verify correct adjustment.

SPEEDOMETER SERVICE
The speedometer driven gear, adapter and vehicle
speed sensor can be serviced with the transfer case in
the vehicle.
SPEEDOMETER COMPONENT REMOVAL/
INSTALLATION (FIG. 4) (1) Shift transfer case into Neutral.
(2) Raise vehicle.
(3) Disconnect wires at vehicle speed sensor.
(4) Loosen and disconnect coupling nut that at­
taches speed sensor to adapter. Then loosen and dis­ connect coupling nut attaching adapter to driven
gear.
(5) Remove vehicle speed sensor and speedometer
adapter. (6) Loosen and remove speedometer driven gear.
(7) Lubricate driven gear with engine or gear oil
and install gear in transfer case. Tighten gear to 11
N*m (100 in. lbs.) torque. (8) Install adapter and speed sensor. Tighten cou­
pling nuts to 17 N»m (150 in. lbs.) torque. (9) Connect wires to speed sensor.
(10) Lower vehicle.

TRANSFER CASE
REMOVAL
(1) Raise vehicle.
(2) Remove drain plug and drain transfer case lu­
bricant. (3) Disconnect vehicle speed sensor wires.
(4) Mark front/rear propeller shafts and yokes for
installation reference. (5) Disconnect and remove propeller shafts. Or dis­
connect shafts at transfer case yokes. Then move shafts aside for working clearance and secure them
to frame rails with wire. (6) Disconnect transfer case shift lever from range
lever on transfer case. (7) Support transfer case with transmission jack.
Secure transfer case to jack with safety chains. (8) Remove nuts attaching transfer case to trans­
mission adapter. (9) Slide transfer case rearward until it is clear of
transmission output shaft.
DISTANCE

SENSOR
ADAPTER
DRIVEN
GEAR
J9021-151

Fig.
4 Speedometer Components.
(10) Lower jack and move transfer case from under
vehicle.
(11) Remove old gasket material from transmission
adapter.

TRANSFER CASE
INSTALLATION
(1) Apply Mopar perfect seal, silicone sealer, or
Permatex No. 2 sealer to both sides of transfer case-
to-transmission gasket. Then position gasket on
transmission. (2) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by ro­
tating transfer case rear output shaft yoke if neces­ sary. Do not install any transfer case attaching
nuts until the transfer case is completely seated against the transmission. (3) Install and tighten transfer case attaching nuts
to 47 N*m (35 ft. lbs.). (4) Install rear crossmember.
(5) Remove jack stand from under transmission.
(6) Align and connect propeller shafts.
(7) Connect vehicle speed sensor wires.
(8) Connect transfer case shift lever to range lever.
Tighten lever locknut to 10 N»m (90 in. lbs.). (9) Fill transfer case with recommended lubricant.
(10) Install transfer case fill plug.
(11) Install skid plate and skid plate crossmember.
(12) Lower vehicle.

TRANSFER CASE DISASSEMBLY
(FIG.
S) REAR RETAINER AND OUTPUT SHAFT
REMOVAL/DISASSEMBL
Y
(1) Loosen rear yoke nut until only 2-3 threads are
holding nut on shaft. (2) Remove bolts attaching rear bearing retainer to

case.

(3) Pull yoke rearward to start rear output shaft
out of clutch. (4) Remove rear yoke nut, washer, seal washer and
yoke.

NP205
TRANSFER CASE
21 - 347
LEGEND FOR NP205 TRANSFER CASE

YOKE NUT
®

WASHER
©
SEAL
WASHER
©
REAR
YOKE
©

OIL SEAL
©

REAR
SEAL RETAINER
©

GASKET
©
SNAP
RING
©

REAR
OUTPUT
SHAFT BEARING
©

SPEEDOMETER
GEAR
®
BEARING RETAINER
-
REAR
©

VENT TUBE CONNECTOR
©

GASKET
©

REAR
OUTPUT
SHAFT SUPPORT
©

BEARING
©

LOW GEAR RETAINING RING
THRUST WASHER
(3/16"
THICK)
©
THRUST WASHER
(1/16"
THICK)
©
LOW GEAR ROLLER BEARINGS
[64)
©

BEARING SPACER
©

LOW GEAR
-
REAR SHAFT
©

THRUST WASHER
(1/16"
THICK)
®

REAR
OUTPUT
SHAFT
©

THRUST WASHER PIN
©

SLIDING CLUTCH

PILOT
BEARING ROLLERS
(15) ©

PILOT
BEARING THRUST
©

WASHER
©
LOCK RING
©

INPUT
GEAR
©

IDLER SHAFT COVER
©
GASKET
IDLER SHAFT
IDLER GEAR BEARINGS
BEARING
RACES

BEARING SPACER
IDLER GEAR
IDLER GEAR BEARING SHIMS
WASHER IDLER SHAFT LOCK NUT
THRUST WASHER
PIN
FRONT
OUTPUT
SHAFT
SLIDING CLUTCH

HIGH
GEAR
THRUST WASHER FRONT
OUTPUT
SHAFT FRONT
BEARING
BEARING SNAP RING
FRONT
OUTPUT
SHAFT REAR
BEARING
BEARING RETAINER
-
FRONT
GASKET
RETAINING RING
THRUST WASHER
(3/16"
THICK)
LOW GEAR
-
FRONT SHAFT
LOW GEAR ROLLER BEARINGS
(S3.
iRING
SPACER
FLANGE
OIL SEAL FRONT SEAL RETAINER
GASKET DRAIN PLUG ©
©
©
©
©
©
® ©
©
®
®
©
©
©
©
©
©^
© ©
®
©
©
CASE
MAGNET AND CLIP

FILL
PLUG
PTO COVER AND GASKET
GEAR
CASE

SHIFT RAIL DETENT BALLS
AND SPRINGS
4WD INDICATOR
LIGHT
SWITCH AND GASKET
SHIFT FORK AND RAIL
-
REAR
WHEEL
INTERLOCK PINS
(2)

FORK-TO-RAIL LOCK PIN
SHIFT RAIL OIL
SEALS

SHIFT RAIL
LINK
RETAINING CLIP
(21

LINK-TO-RAIL
RETAINING
PIN

3
HIFT FORK
AND RAIL
-

FRONT WHEEL INTERLOCK HOLE PLUGS
(4)

FRONT
OUTPUT
SHAFT
BEARING
BEARING SNAP RING

INPUT
SHAFT SNAP RING
ADAPTER OIL SEAL
(2)
GASKET

TRANSFER
CASE
ADAPTER ADAPTER SLEEVE
SLEEVE
RETAINING RING
GASKET

TRANSMISSION
ADAPTER

J9021-149

(5)
Remove rear retainer, rear output shaft and
gears as assembly. (6) Remove rear seal retainer from bearing re­
tainer.
(7) Remove snap ring. (8) Remove rear bearing retainer.

(9)
Remove rear bearing, speedometer gear, shaft
support bearings, thrust washer pin and low gear
from rear output shaft (Fig. 5).
(10) Remove lock ring, thrust washer and pilot
bearing rollers from rear output shaft (Fig. 5).
FRONT OUTPUT SHAFT RETAINER REMOVAL (1) Remove front yoke nut, washer and flange (Fig.

5).

(2) Remove front seal retainer and gasket.
(3) Remove PTO cover and gasket.

(4)
Remove detent plug and 4WD indicator light
switch from case (Fig. 5).

(5)
Remove shift rail detent springs and balls (Fig.

5).
Use pencil magnet to remove these components. (6) Remove bolts attaching front bearing retainer
to case. (7) Tap front output shaft with plastic mallet to
loosen it. Then remove shaft, retainer and gears (Fig.
6).
(8) Remove shaft snap ring (Fig. 7).
(9)
Remove thrust washer, gear, bearings and
spacer.

HAMMER

FRONT

OUTPUT
SHAFT
REAR
BEARING

RETAINER
RH320

Fig. 6
Removing/Installing
Front Output Shaft
SHIFT RAIL, IDLER GEAR, INPUT GEAR AND
FRONT SHAFT REMOVAL (1) Remove adapter and gasket. (2) Remove idler shaft nut and washer.
(3) Remove idler shaft cover plate and gasket.

21 - 352 NP241
TRANSFER
CASE
—
•

Fig.
2
Loosening
Rear Retainer
Fig.
3 Removing/Installing Rear Retainer
(7) Install speedometer driven gear.
(8) Install drain plug. Tighten plug to 54 N-m (40
ft. lbs.). (9) Fill transfer case to edge of fill plug opening
with recommended transmission fluid. (10) Install fill plug. Tighten plug to 54 N-m (40 ft.

lbs.).
(11) Connect propeller shaft. Tighten attaching
bolts to 19 N-m (170 in. lbs.).
(12) Lower vehicle.

SPEEDOMETER
ADAPTER/DISTANCE
SENSOR

SERVICE

ADAPTER/SENSOR
REMOVAL
(1) Raise vehicle.
(2) Remove skid plate and crossmember for access,
if necessary. (3) Remove vehicle speed sensor from pinion gear
adapter (Fig. 4). On models with automatic transmis­
sion, remove sensor adapter as well.
(6) Fill transfer case to bottom edge of fill plug
opening with Mopar ATF Plus, or Dexron II auto­
matic transmission fluid.
(7) Install fill plug. Tighten plug to 54 N«m (40 ft.

lbs.).
(8) Lower vehicle.

SPEEDOMETER
GEAR, SHAFT
SEAL,
BEARING
AND RETAINER SERVICE
The front and rear yokes, output shaft seals, re­
tainers and bearings, and speedometer drive gear can all be serviced with the transfer case in the vehicle.
The following combined procedure outlines removal and installation of these components:

RETAINER
AND
SPEEDOMETER COMPONENT REMOVAL
(1) Raise vehicle.
(2) Remove fill and drain plugs and drain oil from
transfer case. (3) Mark propeller shaft and transfer case yoke for
alignment reference. (4) Disconnect propeller shaft. Secure shaft to un­
derside of vehicle. (5) Remove transfer case yoke retaining nut and
seal washer. Use Special Tool C-3281 to hold yoke
while removing nut. (6) Remove transfer case yoke. (7) Remove retainer seal (if seal or bushing is to be
replaced) using suitable tool.
(8) Install a new seal, if old seal was removed.
(9) Remove speedometer gear from rear retainer.
(10) Mark rear retainer for assembly alignment
reference. (11) Remove retainer attaching bolts and remove
retainer. Pry retainer with screwdrivers to remove it (Fig. 2). (12) Remove rear retainer (Fig. 3). Remove speed­
ometer drive gear, if necessary.
(13) Completely clean off old sealant.
(14) If the retainer or bearing are to be replaced,
remove bearing retainer snap ring from rear retainer
and remove bearing.

RETAINER
AND
SPEEDOMETER COMPONENT INSTALLATION
(1) Install rear output bearing in rear retainer and
install snap ring. (2) Apply a 5 mm (3/16 in.) wide bead of Mopar
Gasket Maker, Loctite 518, or Loctite 573 sealant to
mating surface of rear retainer.
(3) Align retainer case reference marks and install
rear retainer on case. (4) Install and tighten rear retainer attaching
bolts to 24 N«m (18 ft. lbs.). (5) Install output shaft seal (if required).
(6) Install yoke, a new yoke seal washer and yoke
nut. Tighten nut to 149 N-m (110 ft. lbs.) torque.

•

NP241 TRANSFER
CASE
21 - 313
LOCK OIL RING SEAL

ADAPTER

(OVERDRIVE
ONLY)
SPEEDOMETER

PINION
GEAR

ADAPTER
O-RING

SPEEDOMETER
ADAPTER

RETAINER
DISTANCE
SENSOR
J9021-99

Fig.
4 Speedometer
Components

(4) Check vehicle speed sensor mounting area in
pinion adapter. If transmission fluid is found in this area, adapter oil seal is leaking and will have to be
replaced.
(5) Remove bolt and retainer securing pinion gear
adapter to extension housing.

(6)
Carefully work adapter and gear out of hous­
ing. (7) Remove and discard adapter O-ring (Fig. 4).

SPEEDOMETER ADAPTER
OIL
SEAL
REPLACEMENT
Remove adapter oil seal if necessary. Start new
seal in adapter by hand. Then press seal into adapter
with Installer Tool C-4004 until tool bottoms (Fig. 5).
ADAPTER

LOCK
RING

TOOL
(3) Count number of teeth on pinion gear before
installing gear in adapter.
(4) Note range numbers on adapter face (Fig. 6).
These numbers correspond to number of teeth on pin­ ion. (5) Install adapter in housing.

(6)
Rotate adapter until required range numbers
are at six o-clock position (Fig. 6). Be sure adapter
range numbers correspond to number of teeth on pin­ ion. (7) Seat adapter in housing.
(8) Install adapter retainer. Tighten retainer bolt
to 11 N-m (100 in. lbs.) torque.
(9) Install vehicle speed sensor. Tighten sensor
coupling nut to 17 N-m (150 in. lbs.) torque and in­
stall sensor wires.
(10) Check and correct transfer case lubricant level
if necessary.
(11) Install skid plate and crossmember if re­
moved. (12) Lower vehicle.
ADAPTER

O'CLOCK
POSITION

Fig.
6 Indexing Speedometer Adapter
RH75
OIL
SEAL

RH263

Fig.
5
Replacing
Speedometer Adapter
Seal

ADAPTER/SENSOR
INSTALLATION
CAUTION:
Before installing
the
pinion arid adapter

assembly
make sure
the
adapter flange
and its
mounting area
in
transfer case
are
perfectly clean. Dirt
or
sand
will
cause misalignment resulting
in

speedometer pinion gear damage.

(1) Thoroughly clean adapter flange and adapter
mounting surface in extension housing. These sur­
faces must be clean for proper adapter alignment and speedometer operation.
(2) Lubricate adapter oil seal and O-ring with
transmission fluid.

21 - 356 NP241
TRANSFER
CASE

•
TRANSFER
CASE
REMOVAL

(1) Raise vehicle.
(2) Position drain oil container under transfer case.
(3) Remove transfer case drain plug and drain lu­
bricant into container. (4) Disconnect wires at vehicle speed sensor.
(5) Disconnect vacuum hoses at vacuum switch.
(6) Disconnect transfer case shift lever from range
lever. (7) Remove skid plate and skid plate crossmember.
(8) Support transmission with jack stand.
(9) Remove rear crossmember.
(10) Mark front and rear propeller shaft yokes for
assembly reference. (11) Remove front and rear propeller shafts.
(12) Support transfer case with suitable jack. Se­
cure transfer case to jack with safety chains. (13) Remove nuts attaching transfer case to trans­
mission. (14) Move transfer case assembly rearward until
free of transmission output shaft. (15) Lower jack and move transfer case from under
vehicle. (16) Remove all gasket material from rear of
transmission adapter housing.

TRANSFER CASE
INSTALLATION
(1) Apply Mopar Perfect Seal, silicone sealer, or
Permatex No. 2 to both sides of transfer case-to-
transmission gasket. Then position gasket on trans­ mission.
(2) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by ro­
tating transfer case rear output shaft yoke if neces­ sary. Do not install any transfer case attaching
nuts until the transfer case is completely seated against the transmission.
(3) Install and tighten transfer case attaching nuts
to 47 N*m (35 ft. lbs.). (4) Install rear crossmember.
(5) Remove jack stand from under transmission.
(6) Align and connect propeller shafts.
(7) Connect speed sensor wires and vacuum switch

hoses.
(8) Connect transfer case shift lever to range lever.
Tighten lever locknut to 10 N*m (90 in. lbs.). (9) Fill transfer case with recommended transmis­
sion fluid. (10) Install transfer case fill plug.
(11) Install skid plate and skid plate crossmember.
(12) Lower vehicle.

TRANSFER CASE DISASSEMBLY
(2) Remove rear retainer (Figs. 2-3). Remove and
discard retainer seal. (3) Remove upper snap ring that retains speedom­
eter gear on shaft. Then remove speedometer gear (Fig. 1).

Fig.
1
Snap Ring
And Speedometer Gear
Removal/
Installation

(4) Remove shaft lower snap ring (Fig. 2)
(5) Remove oil pump. Remove and discard oil
pump seal. (6) Loosen rear case by prying corners loose to
break sealant bead (Fig. 3).

Fig.
2 Removing/Installing Shaft
Lower
Snap Ring
(7) Remove rear case from front case (Fig. 4)
(8) Remove oil pickup screen, tube and magnet
from rear case.

DRIVE CHAIN, SPROCKET, SHIFT FORK
AND

MAINSHAFT SHAFT REMOVAL
(1) Remove mode spring from shift rail (Fig. 5).
(2) Remove driven sprocket snap ring (Fig. 6).
(3) Remove sprocket and drive chain (Fig. 7). Tilt
mainshaft for clearance if necessary.
RETAINER
AND
REAR CASE
REMOVAL

(1) Remove indicator switch from front case.

•

NP241 TRANSFER
CASE
21 - 361

Fig.
21
Removing
Mainshaft Pilot Bearing
Fig.
22 Installing Mainshaft Pilot Bearing (2) Remove bearing with Tool Handle C-4171 and
Remover C-4610 (Fig. 24).
(3) Clean bearing bore thoroughly.
(4) Install new bearing with Handle C-4171 and
Installer C-4609 (Fig. 25).
(5) Install new seal in rear retainer.

FRONT
OUTPUT
SHAFT
FRONT
BEARING
REPLACEMENT
(1) Remove bearing from front case bore with Tool
Handle C-4171, Remover C-4610 and a shop press (Fig. 26).
(2) Clean bearing bore thoroughly.
(3) Install new bearing with Tool C-4210, Handle
C-4171 and a shop press (Fig. 27).

FRONT
OUTPUT
SHAFT
REAR BEARING
REPLACEMENT
(1) Remove bearing from rear case bore with Re­
mover Tools L-4518-1 and L-4454-1 (Fig. 28).
(2) Clean bearing bore thoroughly.
Fig.
23
Removing
Rear Retainer
Seal

Fig.
24
Removing
Mainshaft Rear (Output) Bearing (3) Install new bearing with Handle C-4171 and
Installer C-4608 (Fig. 29).

TRANSFER
CASE
ASSEMBLY
(1) Lubricate transfer case components with auto­
matic transmission fluid during assembly. (2) If transfer case bearings were replaced, verify
that new bearings do not block any oil feed holes. (3) Assemble input gear, thrust washer and low
range gear. Be sure low range snap ring is fully seated. (4) Install input and low range gear assembly in
front case. Secure input gear with snap ring (Fig.
11).
(5) Install shift sector and new sector shaft seals.
Install range lever on sector shaft and tighten lever
locknut to 30 N*m (22 ft. lbs.) torque. (6) Install range fork and hub (Fig. 9).