Locate the Hi/Lo Shift fork and shaft, spring, spring retainer
and detent ball bearing. Wash them in hot soapy water, rinse well then
blow dry. Install a new rubber
O-ring
on the
shaft.
Install
the Hi/Lo shift fork into the T-case so that it engages the clutch sleeve.
See Fig.1.
Apply a light film of 90W oil on the shift shaft and position
it as shown in Fig.2. Make sure the shift detents face the
hole
in the
shift
fork then
drive
the shaft
into
the case,
through
the
fork
and
into
the
rear
of the case.
Install the shaft retainer.
Make sure the shift fork smoothly slides the clutch sleeve
between the Hi/Lo positions. Drop the detent ball into the hole in the
shift fork then the spring then thread in the spring retainer until the
top of it is below the hole for the small cotter pin. Now check that the
shift fork FIRMLY stops in each detent. If it does not then remove the
shift shaft retainer and rotate the shaft to align the detents properly.
Re-install the shift shaft retainer and re-test.
Install the cotter pin as shown in Fig.
3.
Fig. 4
Extension Housing Parts
Fig. 5
Installing Front Shaft Bearing
Fig. 6
Installing Shaft in Housing
Fig. 7
Installing Rear Race
Fig. 8
Race Installed
Ok gather the parts for the Transfer Extension Housing
as shown in
Fig.4. Wash them in hot soapy water, rinse
well then blow dry.
Install the bearing on the front output shaft as shown in Fig.5.
Drive it all the way to the flange.
Place the extension housing output side up on a firm surface
then insert the shaft and bearing as shown in Fig. 6.
Using a brass drift on the outer race, (not the shaft as you may drive the
shaft out of the bearing) drive the bearing in until it seats. Install the
splt ring bearing retainer removed on Page 1 of the disassembly and shown
in Fig. 11 on that page.
Place the extension housing on a a couple of boards or
the anvil of your press and place the race as shown in Fig.
7. Drive it
in until the race is flush with the outer edge as shown in Fig.
8.
Fig. 9
Clutch Sleeve Installed
Note the tapered end direction!
Fig. 10
Trimming Gasket
Fig.11
Extension Bolted On
Fig. 12
Companion Flange Seal Installed
Slide the front drive clutch sleeve onto the transfer output
shaft as shown in Fig. 9. Note that the tapered
end of this sleeve faces the T-Case NOT the front of the extension!
Find the gasket for the Extension Housing to T-Case. Test
fit it to the bottom of the housing. I had to trim mine just a hair all
the way around on the inside as shown in Fig. 10.
Coat the gasket on BOTH sides with a THIN film of blue RTV.
This
will
keep the gasket from sticking to either surface and will aid in sealing.
Bolt the housing to the T-Case with the 5 8mm x 1.25 bolts.
Tighten in an alternating pattern. See Fig. 11.
Get the companion flange seal, coat the outside edge
with oil, and drive it in until it's flush with the front of the extension
housing. See Fig. 12.
Fig. 13
Top Cover Parts
Fig. 14
Installed Shift Lever/Seal
Fig. 15
Gasket installed
Fig. 16
Top Cover installed
Locate the Top Cover, seal and inner shift lever. Wash them
in hot soapy water, rinse well then blow dry. See Fig.
13.
Drive the new seal in, coat the lip with grease then insert
the shaft as shown in Fig. 14.
Coat the gasket on BOTH sides with a THIN film of blue RTV.
Place gasket on top of T-case as shown in Fig.15.
Locate the wiring loom holder and the 8 8mm x 1.25 bolts.
Place the cover on top of the gasket making sure to align the lever with
the shift fork, insert the bolts. Install the loom holder in the second
bolt on the rear of the
cover
as
shown in
Fig.
16.
Tighten all bolts in an alternating pattern. Thread in the automatic T-Case
vent if it was removed.
