INPUT AND LOW RANGE GEARS
Inspect the low range gear pinions and pinion pins.
Replace the low range gear if any of the pins or pin-
ions are worn or damaged.
Inspect the thrust washers, retainer, and snap-
ring. Replace the snap-ring if bent, or distorted.
Replace the thrust washers and retainer if worn,
cracked or damaged in any way.
Examine the input gear carefully. Be sure the gear
teeth and bearing surfaces are in good condition.
Replace the gear if wear or damage is evident.
Check the input gear pilot bearing. Rotate the
bearing and check for roughness or noise. Also check
bearing position in the bore. The bearing should be
recessed approximately 2.5 mm (0.100 in.) below the
top edge of the bore. The bearing should not be
seated at the bottom of the bore. Replace the bearing
if worn, or roughness is evident. Replace both the
gear and bearing if the bearing is a loose fit in the
bore.
GEAR CASE AND RETAINERS
Examine both case halves and retainers carefully.
Replace any retainer or case half if wear, cracks, or
other damage is evident.
Check condition of the low range annulus gear and
the shift rail bushing in the front case (Fig. 32). The
low range annulus gear is not a serviceable part.
Replace the gear and case as an assembly if the gear
is loose, worn, or damaged. The shift rail bushing is
a serviceable part and can be replaced if necessary.
Check the bushing in the rear retainer. Replace the
bushing if worn or scored.
Examine the sealing surfaces of both case halves
and retainers. Small burrs, or scratches on these sur-
faces can be reduced with crocus cloth or a fine tooth
file.
Examine condition of the shift rail bushing in the
front case. If the bushing is worn or damaged, it can
be removed with a blind hole type puller. A replace-
ment bushing can be installed with a suitable size
driver. Recess the bushing slightly below the edge of
the bore but do not seat it all the into the case.
GEARTRAIN
Inspect the mainshaft splines, gear teeth and bear-
ing surfaces carefully for evidence of wear, or dam-
age. Replace the shaft if necessary. do not attempt to
salvage it if damaged.
The shift rail and range fork are an assembly.
Replace both parts if either is damaged. However, the
nylon pads in the fork can be replaced if worn, or
cracked.
Inspect the transfer case snap-rings closely. Do not
attempt to salvage a distorted snap-ring by straight-ening or reshaping it. Replace any snap-ring that is
distorted, or worn.
Inspect the low range gear, input gear and the gear
thrust washers retainer, and snap-ring. The low
range gear is serviced as an assembly only. Replace
the gear if the case or pinions are damaged.
During inspection, also make sure the seal surface
of the input gear is in good condition. Minor nicks on
this surface can be reduced with crocus cloth. How-
ever, replace the gear if the seal surface is severely
scored or worn.
OIL PUMP AND PROGRESSIVE COUPLING
The oil pump and progressive coupling are not ser-
viceable components. Replace the coupling as an
assembly if it is damaged. Replace the oil pump as
an assembly if the gear teeth are worn, or if the
pump has become damaged.
BEARINGS AND SEALS
The transfer case seals should be replaced during
overhaul. Use new seals in the input gear bearing
retainer, front case and rear retainer. Also replace
the yoke seal washer and the detent plug O-ring.
Check condition of each transfer case bearing.
Replace any bearing exhibiting signs of roughness,
wear, or damage.
Fig. 32 Low Range Annulus Gear Location
1 - LOW RANGE ANNULUS GEAR
2 - SHIFT RAIL BUSHING
WJTRANSFER CASE - NV247 21 - 325
TRANSFER CASE - NV247 (Continued)
(15) Remove front bearing retainer seal with suit-
able pry tool.
(16) Install new front bearing retainer with
Installer 7884 (Fig. 44).
INPUT AND LOW RANGE GEAR
(1) Lubricate gears and thrust washers (Fig. 45)
with transfer case lubricant.
(2) Install first thrust washer in low range gear
(Fig. 45). Be sure washer tabs are properly aligned in
gear notches.
(3) Install input gear in low range gear. Be sure
input gear is fully seated.
(4) Install remaining thrust washer in low range
gear and on top of input gear. Be sure washer tabs
are properly aligned in gear notches.
(5) Install retainer on input gear and install snap-
ring.
(6) Align and install low range/input gear assem-
bly in front case (Fig. 46). Be sure low range gear
pinions are engaged in annulus gear and that input
gear shaft is fully seated in front bearing.
Fig. 44 Install Front Bearing Retainer Seal
1 - FRONT BEARING RETAINER
2 - SPECIAL TOOL 7884
Fig. 45 Input/Low Range Gear Components
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
Fig. 46 Input/Low Range Gear Installation
1 - ANNULUS GEAR
2 - INPUT/LOW RANGE GEAR
WJTRANSFER CASE - NV247 21 - 329
TRANSFER CASE - NV247 (Continued)
