Assembly

A. TRANSFER CASE ADAPTER SUB ASSEMBLY INSTALLATION

Using a brush, apply a thin even coat of machine blue or minium to both tooth surfaces of the driven bevel gear.




B. SPACER INSTALLATION

Install the spacer which has been used so far.




C. TRANSFER CASE SUB ASSEMBLY INSTALLATION

1. Wire the mating marks in mated state, install the transfer case and the transfer case adapter.




2. Tighten the transfer case adapter sub assembly on the transfer case sub assembly to the specified torque.




3. Using the special tool, turn the drive eve gear shaft one turn each in the direction of normal and reverse rotation.

Caution: Do not rotate the drive bevel gear shaft more than one turn as it causes a blurred tooth contact pattern.





4. Check to see the mating mark of the driven bevel gear and the mating mark of the transfer case are matched.




5. Make sure that the contact pattern of the driven bevel gear teeth is correct.

NOTE: See Tooth Contact Adjustment Procedure on next page for the standard tooth contact pattern.




6. Check to see if the backlash between the drive and driven bevel gears is up to specification.

Standard value Bevel gear set backlash: 0.08-0.13 mm (0.0031 - 0.0051 in.)




D. EXTENSION HOUSING ASSEMBLY INSTALLATION

Apply sealant to the flange surface of the adapter and install the housing.

Specified sealant: Mitsubishi genuine Part No.997740 or equivalent.

Caution: Squeeze out the sealant from the tube uniformly without excess or discontinuities.




E. SEALANT TO COVER GASKET APPLICATION

Apply sealant to the both sides of the cover gasket.

Specified sealant: MOPAR Part No.4318034 or Tree Bond Part No. 1141E

TOOTH CONTACT ADJUSTMENT PROCEDURE




1. Standard tooth contact pattern

A. Small end
B. Drive side tooth surface (The side receiving force in forward motion)
C. Big end
D. Coast side tooth surface (The side receiving force in reverse motion)




2. Tooth contact pattern when driven bevel gear is too high

Possible cause: The driven bevel gear is too close to the drive bevel gear.




Remedy: Use a thicker spacer for the driven bevel gear mount adjustment so that the driven bevel gear is further away from the drive bevel gear.




3. Tooth contact pattern when driven bevel gear is too low

Possible cause: The driven bevel gear is further away from the drive bevel gear than necessary.




Remedy: Use a thinner spacer for the driven bevel gear mount adjustment so that the driven bevel gear is closer to the drive bevel gear.





NOTE:

1. If correct tooth contact can not be obtained by replacement of spacer for adjusting driven bevel gear mount, change the spacers for adjustment of drive bevel gear preload and drive bevel gear mount adjustment to those of appropriate thickness as described below and adjust the tooth contact again.

* If the driven bevel gear height is still too small when the thinnest spacer for driven bevel gear mount adjustment [0.13 mm (0.0051 in.)] is used; Change the spacer for drive bevel gear mount adjustment to the next thicker one and change the spacer for drive bevel gear preload adjustment to the next thinner one.

* If the driven bevel gear height is still too large when the thickest spacer for driven bevel gear mount adjustment [0.52 mm (0.0205 in.)] is used; Change the spacer for drive bevel gear mount adjustment to the next thinner one and change the spacer for drive bevel gear preload adjustment to the next thicker one.

Repeat above steps until standard tooth contact pattern is obtained.

2. If the tooth contact pattern cannot be brought close to the standard pattern by the adjustment described above, replace the drive bevel gear and driven bevel gear as a set and adjust the tooth contact again.