For
the sake of convenience, and to better document the procedure,
we removed the transfer case from the vehicle and did
all the work on the bench. Please note that you do not
have to remove the transfer case from the vehicle to perform
the installation. Its approximately 4 to 6 hours of serious
back-time for the novice, unless you have an extra-comfortable
creeper! |
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STEP
1
Drain
the transfer case and detach the rear driveshaft. Make
sure you dispose of the ATF properly, and watch those
u-joint bearing caps! That extra shaft will come in
handy someday, though you will need to have it modified.
Tom can do this if you send it back to him.
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STEP
2
Detach
the front output yoke. Detaching this yoke will make
it a lot easier to disassemble and re-assemble the chain
and gears inside the transfer case.
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STEP
3
The
mainshaft on the rear output location on the transfer
case has a thin metal slinger on over it. You will most
likely have to destroy your slinger because it is on
extremely tight and is extremely fragile. Whatever you
do to remove it, carefully try to avoid damaging the
mainshaft. We removed it by gently tapping away the
edge with a chisel.
NOTE:
This part does not exist on regular 231 transfer cases.
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STEP
4
Immediately
following the removal of the slinger, you will come
to a snap-ring on top of a seal. With snap-ring pliers,
carefully remove the snap-ring, and then go ahead and
pull out the seal. You will not be using the seal again.
NOTE:
This part does not exist on regular 231 transfer cases.
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STEP
5
Yet
another snap-ring prevents us from further dismantling
the rear output bearing housing. Go ahead and use your
snap-ring pliers to remove it. Make sure you are keeping
track of where you put your snap-rings. You'll be using
them again! This one is located immediately next to
the rear output bearing.
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STEP
6
Great!
You've removed all of the seals and snap-rings from
the rear output housing. Now the only thing holding
this this together is a few bolts and some old silicone.
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We'll
be dismantling the transfer case housing and pulling the
mainshaft on PAGE 4. |
PAGE
INTRO 1
2 3 4
5 6
7 8
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TO TECH REPORTS MAIN PAGE
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