Part 3 of 3
REASSEMBLY SERVICE POINTS
A - NEEDLE BEARINGS INSTALLATION
1. Using a socket wrench, press-fit the needle bearing flush with surface A in the clutch housing.
2. Make sure that the side of the bearing with a stamped type number faces surface A.
B - OIL SEAL INSTALLATION
Using a socket wrench, install the control shaft oil seal.
SPRING PIN/LOCK INSTALLATION
Using the special tool, drive a new spring pin and lock pin into position.
CAUTION:
- Do not reuse the spring pin or lock pin.
- Install the spring pin so that its slit will be at right angles to the control shaft center line.
TRANSFER CASE DISASSEMBLY AND REASSEMBLY
REASSEMBLY SERVICE POINTS
A - TRANSFER CASE ADAPTER SUBASSEMBLY INSTALLATION
Using a brush, apply a thin even coat of machine blue or equivalent to both tooth surfaces of the driven bevel gear.
B - SPACER INSTALLATION
Install the spacer which has been used so far.
C - TRANSFER CASE SUBASSEMBLY INSTALLATION
1. With the mating marks in the mated state, install the transfer case and adapter.
2. Tighten the transfer case adapter subassembly on the transfer case subassembly to the specified torque.
3. Using the special tool, turn the drive bevel 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 revolution as it will cause a blurred tooth contact pattern.
4. Check that 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 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 INSTALLATION
Apply Mitsubishi Genuine Part No.997740 or equivalent sealant to the flange surface of the adapter and install the housing.
CAUTION: Squeeze out the sealant from the tube uniformly without excess or discontinuities.
E - SEALANT TO COVER GASKET APPLICATION
Apply MOPAR Part No.4318034 or Tree Bond Part No. 1141E sealant to the both sides of the cover gasket.
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 cannot 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 (0.005 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 (0.020 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.
EXTENSION HOUSING DISASSEMBLY AND ASSEMBLY
REASSEMBLY SERVICE POINTS
A - OIL SEAL INSTALLATION
Using the special tool, install the oil seal.
B - ADHESIVE TO AIR BREATHER APPLICATION
Apply MOPAR Part No.4318025 or equivalent adhesive to the air breather port and tit the air breather in position.
TRANSFER CASE SUBASSEMBLY DISASSEMBLY AND REASSEMBLY
REASSEMBLY SERVICE POINTS
A - OIL SEAL INSTALLATION
Using the special tool, install the oil seal.
B - SPACER INSTALLATION
Install the spacer which has been used so far.
C - DRIVE BEVEL GEAR ASSEMBLY INSTALLATION
Install the transfer case and the drive bevel gear assembly and match the mating marks of the transfer case and the drive bevel gear shaft.
D - SPACER INSTALLATION
Install the spacer which has been used so far.
INSPECTION
DRIVE BEVEL GEAR
Using the special tools, check to see if the turning drive torque of the drive bevel gear is within specification.
Standard Value: 1.7-2.5 Nm (1.23-1.81 ft.lbs.)
CAUTION:
- If the turning drive torque is out of specification, adjust by using adjusting spacers.
- Select spacers of nearly the same thickness for both sides.
TRANSFER CASE ADAPTER DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - LOCK NUT REMOVAL
1. Unstake the lock nut.
2. Remove the driven bevel gear's lock nut by using the special tool.
B - DRIVEN BEVEL GEAR ASSEMBLY REMOVAL
Using a press, remove the driven bevel gear assembly.
C - OUTER RACE REMOVAL
Apply a screwdriver to the outer race and tap it to remove the outer race.
REASSEMBLY SERVICE POINTS
A - SPACER INSTALLATION
Install the spacer which has been used so far.
B - TAPER ROLLER BEARING INSTALLATION
Using the special tool, install the taper roller bearing.
C - DRIVEN BEVEL GEAR ASSEMBLY INSTALLATION
1. After installing the driven bevel gear to the transfer case adapter, match the mating marks.
D - LOCK NUT INSTALLATION
1. Tighten the driven bevel gear's lock nut at the specified torque by using the special tool.
2. Stake the lock nut at two places for locking.
INSPECTION
DRIVEN BEVEL GEAR ASSEMBLY
Using the special tool, check to see if the turning drive torque of the driven bevel gear is up to specification.
Standard value: 1.0-1.7 Nm (0.72-1.23 ft.lbs.)
CAUTION: If the turning drive torque is out of specification, adjust with the adjusting spacer.
DRIVE BEVEL GEAR DISASSEMBLY AND REASSEMBLY
DISASSEMBLY SERVICE POINTS
A - TAPER ROLLER BEARING REMOVAL
Using the special tool, remove the taper roller bearing.
B - DRIVE BEVEL GEAR REMOVAL
Using the special tool, remove the drive bevel gear.
REASSEMBLY SERVICE POINTS
A - DRIVE BEVEL GEAR INSTALLATION
Match the mating marks of the drive bevel gear and the drive bevel gear shaft to assembly.
B - TAPER ROLLER BEARING INSTALLATION
Using the special tool, install the taper roller bearing.
DRIVEN BEVEL GEAR DISASSEMBLY AND ASSEMBLY
DISASSEMBLY SERVICE POINT
A - TAPER ROLLER BEARING REMOVAL
Using the special tool, remove the taper roller bearing.
REASSEMBLY SERVICE POINT
A - TAPER ROLLER BEARING INSTALLATION
Using tile collar, install the taper roller bearing.