Transfer Case Overhaul - AWD: Reassembly
- Evenly apply thin coat of Machine Blue or Red lead to both tooth surfaces of driven bevel gear. Install "O" ring and driven bevel gear mount spacer to transfer case. See Figure . Install transfer case adapter to transfer case, and align mating marks. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
- Using Wrench Adapter (MD991144) and spinner handle, turn driven bevel gear shaft one full turn clockwise and counterclockwise. Remove bolts and transfer case adapter. Check contact pattern of driven bevel gear teeth. See Fig 2 .
- If tooth contact pattern shows that driven bevel gear is too high, select and install thicker spacer for driven bevel gear mount adjustment. If tooth contact pattern shows that driven bevel gear is too low, select and install thinner spacer for driven bevel gear mount adjustment. See DRIVEN BEVEL GEAR MOUNT SPACERS TABLE . Repeat steps 1) through 3) until correct tooth contact pattern is obtained.
- If driven bevel gear is still too high when thickest spacer for mount adjustment is used, change drive bevel gear mount spacer to next thinner spacer and drive bevel gear preload spacer to next thicker spacer. See DRIVE BEVEL GEAR ASSEMBLY under COMPONENTS DISASSEMBLY & REASSEMBLY. Repeat steps 1) through 3) until correct tooth contact pattern is obtained.
- If driven bevel gear is still too low when thinnest spacer for mount adjustment is used, change drive bevel gear mount spacer to next thicker spacer and drive bevel gear preload spacer to next thinner spacer. See DRIVE BEVEL GEAR ASSEMBLY under COMPONENTS DISASSEMBLY & REASSEMBLY. Repeat steps 1) through 3) until correct tooth contact pattern is obtained.
- Using dial indicator, measure backlash between drive and driven bevel gears. See Fig 3 . Backlash should be .0031-.0051" (.080-.130 mm).
- Clean extension housing mating surfaces, and apply bond-type sealant to transfer case adapter flange. Install extension housing, and tighten bolts to specification. See TORQUE SPECIFICATIONS . Apply bond-type sealant to both sides of case cover gasket. Install case cover gasket and case cover. Tighten bolts to specification.
DRIVEN BEVEL GEAR MOUNT SPACERS
| Part No. | Mark | Thickness In (.mm) |
|---|---|---|
| MD720353 | 13 | .0051 (.130) |
| MD720354 | 16 | .0063 (.160) |
| MD720355 | 19 | .0075 (.190) |
| MD720356 | 22 | .0087 (.220) |
| MD720357 | 25 | .0098 (.250) |
| MD720358 | 28 | .0110 (.280) |
| MD720359 | 31 | .0122 (.310) |
| MD720360 | 34 | .0134 (.340) |
| MD720361 | 37 | .0146 (.370) |
| MD720362 | 40 | .0157 (.400) |
| MD720363 | 43 | .0169 (.430) |
| MD720364 | 46 | .0181 (.460) |
| MD720365 | 49 | .0193 (.490) |
| MD720366 | 52 | .0205 (.520) |