Refit

REFIT
1. Ensure that the joint faces of the transfer case and main gearbox extension case are clean.
2. Lubricate the oil seal in the joint face of transfer case, secure the transfer case to the adaptor plate on the lifting hoist and raise the hoist until the input shaft enters the transfer case.

CAUTION: Care must be taken during this operation to ensure that the input shaft splines do not damage the oil seal in the transfer gearbox.

During this process it may be necessary to rotate either one of the drive flanges to engage the input shaft splines.
3. Secure the transfer case to the main gearbox by fitting the nuts to the two studs. Fit the remaining bolts noting that the longest bolt is fitted to the upper left hand bore that locates the hollow dowel and tighten all fasteners to 52 Nm (68-83 ft lb).

Transfer Gearbox High/Low Link Adjustment





4. Ensure that the selector lever at the gearbox is in the neutral position.
5. Set the transfer case lever in a vertical position (at right angles to the center line of the main gearbox), rotate the clevis on the end of the rod clockwise or counter clockwise which will shorten or lengthen the operating rod until the hole in the clevis aligns with the hole in the selector lever.
6. Fit the clevis pin and retaining clip assembly. Select high and low transfer to ensure full engagement is occurring. Repeat the above procedure if full engagement is not achieved.
7. Complete the refitting procedure by reversing the removal sequence, noting the following important points.
8. After removing the lifting hoist and adaptor plate from the transfer case, clean the threads of the bolts for the transfer case and fit them together with the mounting bracket to the gearbox. Tighten to 52 Nm (68-83 ft lb).
9. Fit the three bolts which secure the right hand mounting bracket to the chassis. Tighten to 52 Nm (29-37 ft lb).
10. Fit the drive shafts and tighten to 41-52 Nm (30-38 ft lb).
11. Remove the transfer case combined oil filler and level plug, refill the transfer case with the correct grade and quantity of oil until the oil starts to seep from the filler/level hole. Coat the plug with Hylomar sealant and refit the combined filler and level plug. Tighten to 19-30 Nm (14-22 ft lb), wipe away any surplus oil.
12. Check, and if necessary top up the oil level in the main gearbox. Use the correct grade oil.
13. Check the operation of the parkbrake and adjust as necessary.