Transfer Box: Installation
- Clean mounting and mating faces.
- Lubricate new mounting and bore in transfer gearbox casing to aid assembly.
- Position new mounting to rear face of transfer gearbox, and start entry. Mounting to be parallel, with timing marks aligned.NOTE: Transfer timing mark to side of mounting to assist with alignment.
- Lubricate center screw LRT-41-018/4 with Molybdenum Disulfide grease and assemble tool as shown, to fit mounting to transfer gearbox. Start with the center screw at full length and when the mounting is approximately 75 percent fitted, reduce the length of the center screw by screwing it fully into the base plate LRT-41-018/1. This will ensure the center screw LRT-41-018/4, does not foul on the gearbox fluid pan. See Fig 1.CAUTION: Ensure tool alignment indicator is at the 6 o'clock position.
- Ensure the mounting is fitted parallel. If necessary, use a mallet and tap the base plate to maintain a parallel fit.
- Fit multiplug brackets, tighten bolts to 25 Nm (18 ft. lbs.).
- Clean transfer gearbox and mating face dowels and dowel holes.
- Clean input shaft and mating face.
- Apply thin coat of anti-seize grease to shaft splines.
- Fit transfer gearbox and tighten Torx bolts to 43 Nm (32 ft. lbs.).
- Connect multiplug.
- Connect breather hose to gearbox.
- Fit and secure oxygen sensor leads.
- Remove support from transfer gearbox.
- Fit snubbers.
- Fit cross member to mounting, fit nut and bolt but do not tighten at this stage.
- Raise gearbox on jack.
- Align cross member, fit bolts and tighten to 68 Nm (50 ft. lbs.).
- Remove support from gearbox.
- Tighten nut and bolt securing mounting to cross member to 100 Nm (74 ft. lbs.).
- Fit heat shield and secure with nuts.
- Fit rear propeller shaft.
- Fit front propeller shaft.
- Refill transfer gearbox with oil.
- Fit fan to pulley and tighten viscous coupling nut to 45 Nm (33 ft. lbs.).