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1. Drain oil from bottom plug in transfer case. Then remove
the transfer case from the vehicle. Disconnect the mounting brackets from the case. Save
all hardware.
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2. Remove rubber boot. Remove shifter stick. To remove stick, push down and turn to unlock it
from the throat. Remove stick and spring assembly.
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3. Remove the Rubber sheet ring from the large throat. This
item is extremely important and cannot be overlooked. If the ring is cracked and degraded,
it will need to be replaced. Using a worn out ring will cause major problems during
shifting. OEM part # 29541-80051
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4. Next remove the electrical light switch wire with a
wrench.
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5. Dump out the check ball from the small opening.
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6. The Drive shaft flanges have crimped nuts. Uncrimp the
nuts using a pointed punch and hammer. The best way to take off the nuts is using a air
impact driver to spin the nuts off. The nuts can be re-crimped during the reassembly
process.
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7. Remove the 3 flanges. Use a gear puller if necessary.
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8. On the bottom of transfer case, loosen gear shift locating
spring plug and take out spring and locating ball. It is helpful to use a small pointed
object such as a center punch or ball point pen to remove these items. Spray carb cleaner
or similar liquid into the hole to loosen these items.
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9. Remove speedometer driven gear case bolt and remove
speedometer driven gear from case using plyers.
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10. Remove bolts securing transfer front case, and take off
case. Save bolts.
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11. Remove counter
shaft lock plate bolt and plate.
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12. Remove bolts fastening center case and rear case
together.
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13. Using a hammer, lightly tap on the case lug to separate
the case halfs approx 1/16".
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14. Next, use large slotted screwdriver or similar object to
lightly pry case halfs apart. Check shift rods for any binding that may occur during this
step. Pry the case apart by hand after checking shift rods.
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15. Place your
thumb or finger over the opening before rotating the shift fork rod as shown. Remove the
spring and check ball from the opening. Use caution as the spring and ball will come out
rapidly when the fork is rotated.
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16. Remove counter gear from case by sliding gear off of
large shaft. Remove needle bearings, spacer,
large shaft and thrust washer from case. Remove thrust washer from opposite side case.
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17. Remove input shaft from center case. Tap lightly with
plastic hammer
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18. Remove shift shaft as shown.
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19. Next, hold case,
use block of wood or similar surface and lightly bump the end of the shaft to dislodge
output shaft from rear case. Remove stock shim from case before cleaning.
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20. On the output
shaft, remove circlip from hub as shown.
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21. Use a gear puller
to remove high output gear, thrust washer, bearing and hub. When using the gear puller, it
is likely that the teeth on the gear will become chipped. This is not an issue as this
gear will be replaced will a new high output gear
included in the Rockcrawler DL kit.
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22. Use a press to
remove the low output gear from the main shaft. Also remove the thrust washer, bearing and
hub.
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23. After the gears
are removed from shaft, begin to install new high & low output gears. Install the new
low output gear in the reverse order of disassembly
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24. After low output gear is pressed into place,
install new high output gear on main shaft
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25.Install the
assembly using an H-frame press, or use a socket or similar object that matches the
diameter of the hub and tap on with a hammer gently. Re-install circlip.
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26. Remove bearing
from the input shaft using H-frame press or bearing puller.
Install same bearing onto new supplied input shaft
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27. Clean your parts.
Inspect all neoprene seals for condition and replace if necessary. After cleaning case,
re-install shim removed in step 19 using a light coat of grease to hold in place.
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28. In center case,
install spring and ball. Use a blunt driver
to hold the spring into the hole and press inward. Install the shift fork shaft into the
hole and rotate.
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29. After rotation,
install center ball. Slide shaft out until ball drops in flush.
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30. Apply shift fork
to output shaft.
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31. Install sleeve
(coupler) ring onto the fork. Install shaft assembly into center case.
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32. Install new input
shaft assembly into case center.
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33. Apply light film
of grease to a thrust washer and apply to rear case.
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34. Do the same to the
opposite case and insert the large shaft flush with hole.
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35. Install new
ROCKCRAWLER DL COUNTER GEAR. Push shaft from opposite side of case thru the new gear.
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36. Install needle
bearing, then the spacer, then another bearing.
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37. Install new gasket
to the back half of case.
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38. Assemble rear case to the center case as shown. Install
case bolts as shown.
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39. Install the counter shaft lock plate and bolt. Torque to
7.0- 12.0 ft lbs.
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40. Line up shift rod gates as shown
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41. Insert check ball and spring. Install bolt plug and
tighten with allen wrench.
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42. Apply gasket to case front cover and install cover using
same bolts. Torque 9.5 to 16.5 lb/ft.
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43. Using a torque wrench, torque case bolts 9.5 to 16.5
lb/ft.
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44. Install speedometer driven gear and case bolt.
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45. Install check ball and the electrical light switch wire
with a wrench.
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46. Install rubber sheet ring into shifter throat.
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47. Re-install shift rod and spring.
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48. Note: flanges are different. Two are the same and one is
different. Install flanges correctly and tighten crimp nuts. Torque to 80.0 to 108.0 ft
lbs. Be sure to re-crimp the flange nuts with hammer and punch.
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49. Install the mounting brackets and hardware.
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50. Install transfer case into vehicle and fill with gear oil
before starting the vehicle.
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ZW