Posted by Vaughn on Sunday, June 13, 2004 at 11:44AM :
In Reply to: transfer case question posted by Jim on Saturday, June 12, 2004 at 1:28PM :
You can assemble the retainers without the lip on the case and drive the cup till it seats. Normally you would use a cup drift and hammer untill you here the cup seat by a high pitch ping and solid noise when striking the drift by the hammer. On the cover side assemble the retainer and shims and do the same. Make sure the retainers are laying against a flat surface when you do this and don't hit real hard with the hammer, just enought to move the cup down the case.
To check the idler gear play:
Leave the other gears out and assemble the idler gear and place the short section in case with the long section towards the cover. Place on a new gasket, tappered pins, cover on and long bolts in center of cover. Tighten the bolts to 35 ft lbs. Remove the pipe plug and install a 3/8-16 x 1-3/4 in the threaded hole of the idler shaft. Turn the bolt till it seats then try to move the shaft forward and backward to determine if there is any end play. Spin the idler gear to determine if it is free rolling with no end play. Grab the gear and try and move it forward and backward, side to side. If adjustment is necessary, remove the retainer and a thin shim, reassemble and check again. Once adjusted take case apart and assemble driven gears and re-assemble case. Place yokes or companion flanges on and tighten nuts, then check for bearing play. If adjustment is needed take off yokes and retainer and remove thin shim, check again.
Check bearing play with clean dry bearings - do no oil! Once assembly is finish poor oil in case and move case around to get oil on bearings
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