AMC Coupes/Sedans/Wagons 1975-1988 Repair Information

Transfer Case

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REMOVAL & INSTALLATION



With Manual Transmission

See Figures 1 and 2

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Fig. Fig. 1: Remove the gearshift cover and unfasten the transfer case upper mounting nut



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Fig. Fig. 2: Location of the manual transmission brace, bracket and related components

Steps 1 through 6, below, pertain to models with the SR-4 transmission only.

  1. Shift the transmission into Neutral.
  2.  
  3. Remove the screws attaching the gearshift lever bezel to the floorpan or console, if equipped.
  4.  
  5. Side the bezel and boot upward on the gearshift to provide access to the lever attaching bolts.
  6.  
  7. Remove the bolts attaching the gearshift lever to the lever mounting cover on the transmission adapter housing and remove the lever.
  8.  
  9. Remove the bolts attaching the gearshift lever mounting cover to the transmission adapter housing and remove the cover.
  10.  
  11. Remove the nut from the transfer case mounting stud located inside the transmission adapter housing.
  12.  
  13. Raise the automobile.
  14.  
  15. Remove the skid plate and rear brace rod at the transfer case.
  16.  
  17. Remove the speedometer adapter retainer attaching bolt and remove the retainer, adapter, and cable. Plug the adapter opening in the transfer case to prevent excessive oil spillage.
  18.  

Mark the position of the speedometer adapter for assembly reference before removing it.

  1. Mark the driveshafts and axle yokes for assembly alignment reference and disconnect the driveshafts at the transfer case.
  2.  
  3. On 1982 models, remove the transfer case shift motor vacuum harness.
  4.  
  5. Support the transfer case with a transmission jack.
  6.  
  7. Remove the nuts from the transfer case mounting stud nuts. Remove the transfer case.
  8.  

To install:
  1. Align the transmission output and transfer case input shafts and install the transfer case on the transmission adapter housing.
  2.  
  3. Install and tighten the transfer case mounting stud nuts to 33 ft.lb. torque.
  4.  
  5. Remove the jack used to support the transfer case.
  6.  
  7. Align and connect the driveshafts to the axle yokes. Tighten the clamp strap bolts to 15 ft. lbs. torque.
  8.  
  9. Install the replacement O-ring on the speedometer adapter and install the adapter and cable and retainer. Tighten the retainer bolt to 100 inch lbs.
  10.  


WARNING
Do not attempt to reuse the original adapter O-ring. The O-ring is designed to swell in service to improve its sealing qualities and could be cut or torn during installation if reuse is attempted.

  1. Install the skid plate and rear brace rod. Torque the retaining bolts to 30 ft. lbs.
  2.  
  3. On 1982 models, install the transfer case shift motor vacuum harness.
  4.  
  5. Check and correct the lubricant levels in the transmission and transfer case if necessary.
  6.  
  7. Lower the automobile.
  8.  

Steps 23 through 26, below, pertain to models with the SR-4 transmission only.

  1. Install the nut on the transfer case mounting stud located inside the transmission adapter housing. Tighten the nut to 33 ft. lbs.
  2.  
  3. Install the gearshift lever on the mounting cover on the transmission adapter housing.
  4.  
  5. Install the gearshift lever on the mounting cover. Be sure lever is engaged with the shift rail before tightening the lever attaching bolts.
  6.  
  7. Position the gearshift lever boot and bezel on the floorpan or console, if equipped, and install the bezel attaching screws.
  8.  

With Automatic Transmission See Figure 3

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Fig. Fig. 3: Automatic transmission brace, bracket and retainer locations

  1. Raise the automobile.
  2.  
  3. Support the engine and transmission with a support stand or transmission jack.
  4.  
  5. Disconnect the catalytic converter support bracket at the adapter housing.
  6.  
  7. Remove the skid plate and rear brace rod at the transfer case.
  8.  
  9. Remove the speedometer cable and adapter from the transfer case. Discard the adapter O-ring; it is not reusable.
  10.  
  11. Mark the driveshafts and transfer case yokes for assembly reference.
  12.  
  13. Disconnect the driveshafts at the yokes. Secure the shafts to the underside of the automobile.
  14.  
  15. Disconnect the gearshift and throttle linkage at the transmission.
  16.  
  17. Lower the rear crossmember.
  18.  
  19. Remove the transfer case-to-adapter housing stud nuts and remove the transfer case.
  20.  

To install:
  1. Install the transfer case on the adapter housing. Do not damage the output shaft splines during installation.
  2.  
  3. Install the transfer case-to-adapter housing stud nuts. Tighten the nuts to 33 ft. lbs. torque
  4.  
  5. Install the rear crossmember. Tighten the crossmember attaching nuts to 30 ft. lbs. torque.
  6.  
  7. Install the rear brace rod.
  8.  
  9. Remove the transmission jack or support stand.
  10.  
  11. Connect the gearshift and throttle linkage to the transmission.
  12.  
  13. Connect the driveshafts. Tighten the clamp strap bolts to 15 ft.lb. torque.
  14.  
  15. Install a new O-ring on the speedometer adapter and install the adapter and cable in the transfer case.
  16.  

Do not attempt to reuse the old adapter O-ring. The O-ring is designed to swell in service to provide improved sealing qualities and could be cut or torn if reinstallation is attempted.

  1. Install the skid plate and stiffening brace, if equipped. Tighten the retaining bolts to 30 ft. lbs.
  2.  
  3. Connect the catalytic converter support bracket to the adapter housing.
  4.  
  5. Check and adjust the transfer case lubricant level and transmission linkage adjustments if necessary.
  6.  
  7. Lower the automobile.
  8.  

 
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