Jeep CJ/Scrambler 1971-1986 Repair Guide

Quadra-Trac® Overhaul

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DISASSEMBLY



See Figures 1 and 2

  1. Drain the lubricant from the case.
  2.  
  3. Remove the front and rear output shaft yokes and discard the yoke seal washers and yoke nuts.
  4.  
  5. Mark the rear retainer and rear case for an alignment reference.
  6.  
  7. Unbolt and remove the rear retainer. If necessary, use a soft mallet to loosen the retainer. Under no circumstances should the retainer be pried off.
  8.  
  9. Remove the differential shims and speedometer drive gear from the rear output shaft. Mark the shims for reference.
  10.  
  11. Remove the rear output bearing snapring and remove the bearing from the retainer using a soft mallet.
  12.  

The rear output bearing has one side shielded. Note this for reassembly.

  1. Remove the rear output shaft seal from the retainer using a small prybar or punch.
  2.  
  3. Position the front case assembly on wood blocks. The blocks should have V cuts made in them for more positive support of the case.
  4.  
  5. Remove the case halve bolts. The case halves may be pried apart using a small prybar in the notches provided at the case ends.
  6.  

The two case end bolts have flat washers and alignment dowels. Note their location for assembly.

  1. Remove the rear output shaft and viscous coupling as an assembly. Tap the shaft with a plastic mallet if necessary.
  2.  
  3. Remove the O-ring seal and pilot roller bearings from the main shaft.
  4.  
  5. Remove the rear output shaft from the viscous coupling.
  6.  
  7. Remove the shift rail spring from the rail.
  8.  
  9. Remove the plastic oil pump from the shaft bore in the rear case. Note the pump position for assembly reference. The end with the recess must face the shaft bore when installed.
  10.  
  11. Remove the rear output shaft bearing seal from the case. A small prybar may be used to pry it out.
  12.  
  13. Remove the front output shaft thrust bearing assembly. Remove the thick washer, bearing and thin washer.
  14.  
  15. Remove the driven sprocket retaining snapring.
  16.  
  17. Remove the drive sprocket, drive chain, driven sprocket, side gear clutch and clutch gear as an assembly. Place the assembly on a workbench and mark the components for assembly.
  18.  
  19. Remove the needle bearings and spacers from the main shaft and side gear bore. A total of 82 bearings and three spacers is used.
  20.  
  21. Remove the side gear/clutch gear assembly from the drive sprocket. Remove two snaprings and remove the clutch gear from the side gear.
  22.  
  23. Remove the side gear clutch, main shaft thrust washer and remaining main shaft needle bearing spacer.
  24.  
  25. Remove the front output shaft and shaft thrust bearing assembly. Note the installation sequence of the bearing assembly.
  26.  
  27. Remove the front output shaft seal from the front case using a small prybar or punch.
  28.  
  29. Remove the shift rail spring from the shift rail.
  30.  
  31. Remove the clutch sleeve, mode fork and spring as an assembly.
  32.  
  33. Remove the main shaft thrust washer and main shaft. Grasp the shaft and pull it straight up and out.
  34.  
  35. Move the range operating lever downward to the last detent position.
  36.  
  37. Disengage the range fork lug from the range sector slot.
  38.  
  39. Remove the annulus gear retaining snapring and thrust washer.
  40.  
  41. Remove the annulus gear and range fork.
  42.  
  43. Remove the planetary thrust washer from the hub.
  44.  
  45. Remove the planetary assembly.
  46.  
  47. Remove the main shaft thrust bearing from the input gear.
  48.  
  49. Remove the input gear and remove the input gear thrust bearing and race.
  50.  
  51. Remove the range selector detent ball and spring retaining bolt and remove the detent ball and spring.
  52.  
  53. Remove the range selector and operating lever attaching nut and lockwasher, and remove the lever.
  54.  
  55. Remove the range selector.
  56.  
  57. Remove the range selector O-ring and retainer.
  58.  
  59. Remove the input gear oil seal from the front case with a small prybar.
  60.  



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the Warner Quadra-Trac® transfer case without low range



Click image to see an enlarged view

Fig. Fig. 2: Exploded view of the Warner Quadra-Trac® transfer case with low range

ASSEMBLY



Lubricate all parts before assembly with 10W-30 motor oil. Petroleum jelly will be indicated for some assemblies. Do not use chassis lube or other heavy lubricants.

  1. Install new input gear and rear output shaft bearing oil seals. Seat the seals flush with the edge of the seal bore or with the seal groove in the case. Coat the seal lips with petroleum jelly after installation.
  2.  
  3. Install the input gear thrust bearing race in the case counterbore.
  4.  
  5. Install the input gear thrust bearing on the input gear and install the gear and bearing in the case.
  6.  
  7. Install the main shaft thrust bearing in the bearing recess in the input gear.
  8.  
  9. Install the planetary assembly on the input gear. Make sure that the planetary pinion teeth mesh fully with the input gear.
  10.  
  11. Install the planetary thrust washer on the planetary hub.
  12.  
  13. Install a new sector shaft O-ring and retainer in the shaft bore in the case.
  14.  
  15. Install the range selector in the front case. Install the operating lever on the sector shaft and install the lever attaching washer and locknut on the shaft. Tighten the locknut to 17 ft. lbs.
  16.  
  17. Install the detent spring, ball and retaining bolt in the front case detent bore. Tighten the bolt to 22 ft. lbs.
  18.  
  19. Move the range selector to the last detent position.
  20.  
  21. Assemble the annulus gear and range fork. Install the assembled fork and gear over the planetary assembly. Be sure that the annulus gear is fully meshed with the planetary pinions.
  22.  
  23. Insert the range fork lug in the range detent slot.
  24.  
  25. Install the annulus thrust washer and retaining ring on the annulus gear hub.
  26.  
  27. Align the main shaft thrust washer in the input gear, if necessary.
  28.  
  29. Install the main shaft. Be sure the shaft is fully seated in the input gear.
  30.  
  31. Install the main shaft thrust washer on the main shaft.
  32.  
  33. Install the short main shaft needle bearing spacer on the shaft.
  34.  
  35. Apply a liberal coating of petroleum jelly to the main shaft needle bearing surface and install 41 of the 82 needle bearings on the shaft. Be sure the bearings seat on the short spacer.
  36.  
  37. Install the long needle bearing spacer on the shaft. Lower the spacer onto the previously installed needle bearings carefully to avoid displacing them.
  38.  
  39. Align the shift rail bore in the case with the bore in the range fork and install the shift rail.
  40.  

Remove all traces of oil from the case shift rail bore before installing the rail. Oil in the case bore may prevent the rail from seating completely and prevent rear case installation.

  1. Assemble the mode fork, mode fork spring and mode fork bracket.
  2.  
  3. Install the clutch sleeve in the mode fork. Be sure the sleeve is positioned so that the ID numbers on the sleeve face upward when the sleeve is installed.
  4.  
  5. Align the clutch sleeve and mode fork assembly with the shift rail and install the assembly on the shift rail and main shaft. Be sure that the clutch sleeve is meshed with the main shaft gear.
  6.  
  7. Lubricate the remaining 41 needle bearings and place them on the main shaft.
  8.  
  9. Install the side gear clutch on the main shaft with the teeth facing downward. Be sure the gear teeth mesh with the clutch sleeve.
  10.  
  11. Install the remaining short main shaft needle bearing spacer. Install the spacer carefully to avoid displacing previously installed bearings.
  12.  
  13. Install the front output shaft front thrust bearing in the front case. Correct sequence is thick race, bearing, thin race.
  14.  
  15. Install the front output shaft in the front case.
  16.  
  17. Install the clutch gear on the side gear. The tapered side of the clutch gear teeth must face the side gear teeth.
  18.  
  19. Install the clutch gear and drive sprocket locating snaprings on the side gear. Install the snaprings so that they face each other.
  20.  
  21. Position the drive and driven sprockets in the drive chain and install the assembled side and clutch gears in the drive sprocket.
  22.  
  23. Install the assembled drive chain, sprockets and side gear on the main shaft and front output shaft. Align the sprockets with the shaft, keeping the assembly level and carefully lower the assembly onto both shafts simultaneously. Do not displace any of the needle bearings.
  24.  
  25. Install the driven sprocket retaining snapring.
  26.  
  27. Install the front output shaft rear thrust bearing assembly on the front output shaft. Correct installation sequence is thin race, thrust bearing, thick race.
  28.  
  29. Install the shift rail spring on the shift rail.
  30.  
  31. Install a new O-ring on the main shaft pilot bearing hub.
  32.  
  33. Coat the main shaft pilot roller bearing hub and bearings with a liberal amount of petroleum jelly and install the rollers on the shaft.
  34.  
  35. Install the rear output shaft in the viscous coupling. Be sure it is fully seated.
  36.  
  37. Install the assembled viscous coupling and rear output shaft on the main shaft. Align the main shaft pilot hub with the pilot bearing bore in the rear output shaft and carefully lower the assembly onto the main shaft. Take care to avoid displacing the roller bearings.
  38.  
  39. Align the clutch gear teeth with the viscous coupling teeth and seat the coupling fully onto the clutch gear.
  40.  

When correctly installed, the clutch gear teeth will not be visible or extend out of the coupling.

  1. Install the magnet in the front case, if removed.
  2.  
  3. Clean the mating surfaces of the case halves thoroughly.
  4.  
  5. Apply Loctite®515 or equivalent to the mating surfaces and all attaching bolts.
  6.  
  7. Join the case halves, aligning the dowels and install the bolts. Torque the bolts to 22 ft. lbs.
  8.  

The two end bolts require flat washers.

  1. Install the oil pump on the rear output shaft and seat it in the case. The side with the recess should face the inside of the case.
  2.  
  3. Install the speedometer drive gear and differential shift, on the output shaft.
  4.  
  5. Install the vent chamber seal in the rear retainer.
  6.  
  7. Align and install the rear retainer on the case. Make the retainer finger tight only.
  8.  
  9. Install the yoke on the rear output shaft. Make the yoke finger tight only.
  10.  
  11. Mount a dial indicator on the rear retainer. Position the indicator stylus so that it contacts the top of the yoke nut.
  12.  
  13. Install the yoke on the front output shaft and rotate the shaft ten complete revolutions.
  14.  
  15. Rotate the front output shaft again and note the play indicated on the dial. End play should be 0.002-0.010 in. (0.05-0.25mm). If the end play must be adjusted, remove the rear retainer and add or subtract shims as required.
  16.  
  17. Remove both output shaft yokes and discard the nuts.
  18.  
  19. Install the front and rear yoke seals.
  20.  
  21. Remove the rear retainer bolts, apply Loctite®515 or equivalent to the mating surface of the retainer and to the bolts and install the bolts. Torque them to 22 ft. lbs.
  22.  
  23. Install new yoke seal washers on the output shafts, install yokes on the shafts and install new yoke nuts. Tighten the nuts to 110 ft. lbs.
  24.  
  25. Install the drain plug and tighten to 18 ft. lbs.
  26.  
  27. Pour 4 pints of 10W-30 motor oil into the case and install the fill plug. Tighten it to 18 ft. lbs.
  28.  

 
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