Jeep CJ 1945-1970 Repair Information

Transfer Case

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REMOVAL & INSTALLATION



The transfer case can be removed without removing the transmission.

  1. Drain the transfer case and transmission and replace the drain plugs.
  2.  
  3. Disconnect the brake cable.
  4.  
  5. Disconnect the front and rear driveshafts at the transfer case.
  6.  
  7. Disconnect the speedometer cable at the transfer case.
  8.  
  9. Disconnect the transfer case shift levers. On vehicles equipped with two shift levers loosen the set screw and remove the pivot pin. Use a prying tool to pry the shift lever springs away from the shift levers. On models equipped with a single shift lever remove the pivot pin cotter key and the adjusting rod attaching nut to remove the shift lever.
  10.  
  11. Remove the cover plate on the rear face of the transfer case or Power Take-Off (PTO) shift unit. Remove the cotter key, nut and washer from the transmission main shaft.
  12.  
  13. If possible, remove the transfer case main drive gear from the transmission main shaft. If it is not possible, continue on.
  14.  
  15. Remove the transmission-to-transfer case mounting bracket bolt and nut.
  16.  
  17. Remove the transmission-to-transfer case attaching bolts.
  18.  
  19. Remove the transfer case. If the transfer case main drive gear has not been removed in Step 7, proceed as follows:
    1. Brace the end of the transmission main shaft so that it cannot be moved in the transmission, then pull the transfer case to the rear to loosen the gear.
    2.  
    3. Remove the gear.
    4.  
    5. When separating the two housings, be careful that the transmission main shaft bearing, which bears in both housings, remains in the transmission case.
    6.  

  20.  
  21. If the transfer case is being removed from the transmission with the two units out of the vehicle, use the above procedure starting from Step 6 and replacing Step 10 with the following procedure:
    1. Remove the transmission shift housing.
    2.  
    3. Install a transmission mainshaft retaining plate, tool W-194, to prevent the mainshaft from pulling out of the transmission case.
    4.  
    5. Should this tool be unavailable, loop a piece of wire around the mainshaft directly in back of the mainshaft second speed gear.
    6.  
    7. Install the transmission shift housing right and left front attaching bolts part way into the transmission case.
    8.  
    9. Twist the wire and attach each end to one of the screws.
    10.  
    11. Tighten the wire.
    12.  
    13. With the mainshaft securely in place, support the transfer case and with a rawhide mallet or brass drift and hammer, then tap lightly on the end of the mainshaft to loosen the gear and separate the two units.
    14.  

  22.  

To install:
  1. Install the transfer case. If the transfer case main drive gear was not removed in Step 7, proceed as follows:
    1. Install the gear.
    2.  
    3. When separating the two housings, be careful that the transmission mainshaft bearing, which bears in both housings, remains in the transmission case. When installing the transfer case gear on the transmission rear splined driveshaft, tighten the large gear nut securely and insert the cotter pin. Sink the cotter pin well into the nut slots so it will clear the PTO drive, if so equipped.
    4.  
    5. Brace the end of the transmission main shaft so that it cannot be moved in the transmission, then pull the transfer case to the rear to loosen the gear.
    6.  

  2.  
  3. Remove transmission mainshaft retaining plate, tool W-194, or the wire.
  4.  
  5. Install the transmission shift housing. When installing the rear adapter plate on a 4-speed transmission, be sure that the cap screw heads do not protrude beyond the adapter plate face and that they do not interfere with the transfer case fitting tightly against the rear adapter plate.
  6.  
  7. Install the transmission-to-transfer case attaching bolts.
  8.  
  9. Install the transmission-to-transfer case mounting bracket bolt and nut.
  10.  
  11. Install the transfer case main drive gear on the transmission main shaft.
  12.  
  13. Install the cotter key, nut and washer from the transmission main shaft.
  14.  
  15. Install the cover plate on the rear face of the transfer case or PTO shift unit.
  16.  
  17. Connect the transfer case shift levers. On vehicles equipped with two shift levers loosen the set screw and Install the pivot pin. On models equipped with a single shift lever install the pivot pin cotter key and the adjusting rod attaching nut to install the shift lever.
  18.  
  19. Connect the speedometer cable at the transfer case.
  20.  
  21. Connect the front and rear driveshafts at the transfer case.
  22.  
  23. Connect the brake cable.
  24.  
  25. Fill the transfer case and transmission.
  26.  

 
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