Jeep CJ/Scrambler 1971-1986 Repair Guide

Case Assembly

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REMOVAL & INSTALLATION



1971 Models

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 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: 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. Remove the gear. When separating the two housing, be careful that the transmission main shaft bearing, which bears in both housings, remains in the transmission case.
  20.  

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. Install a transmission mainshaft retaining plate, tool W-194, to prevent the mainshaft from pulling out of the transmission case. Should this tool be unavailable, loop a piece of wire around the mainshaft directly in back of the mainshaft second speed gear. Install the transmission shift housing right and left front attaching bolts part way into the transmission case. Twist the wire and attach each end to one of the screws. Tighten the wire. 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.
  2.  
  3. 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 power take-off 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.  

  4.  
  5. Remove transmission mainshaft retaining plate, tool W-194, or the wire.
  6.  
  7. 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.
  8.  
  9. Install the transmission-to-transfer case attaching bolts.
  10.  
  11. Install the transmission-to-transfer case mounting bracket bolt and nut.
  12.  
  13. Install the transfer case main drive gear on the transmission main shaft.
  14.  
  15. Install the cotter key, nut and washer from the transmission main shaft.
  16.  
  17. Install the cover plate on the rear face of the transfer case or power take-off shift unit.
  18.  
  19. 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.
  20.  
  21. Connect the speedometer cable at the transfer case.
  22.  
  23. Connect the front and rear driveshafts at the transfer case.
  24.  
  25. Connect the brake cable.
  26.  
  27. Fill the transfer case and transmission.
  28.  

1972-75 Models
  1. Remove the transfer case shift lever knob and trim ring and boot.
  2.  
  3. Remove the transfer case shift lever.
  4.  
  5. Lift and support the vehicle.
  6.  
  7. Drain the transfer case lubricant.
  8.  
  9. Mark the yokes for reference during assembly and disconnect the front and rear driveshafts from the transfer case.
  10.  
  11. Install the transfer case drain plug.
  12.  
  13. Disconnect the parking brake cable at the equalizer and mounting bracket.
  14.  
  15. Disconnect the speedometer cable.
  16.  
  17. Remove the screws which attach the transfer case to the transmission. Install two 3 / 8 in. x 4 in. threaded dowel pins, one on each side of the case.
  18.  
  19. Remove the transfer case.
  20.  
  21. Remove the gasket between the transmission and the transfer case.
  22.  
  23. Place a new gasket on the dowel pins in the transmission case before installing the transfer case back onto the transmission.
  24.  
  25. Shift the transfer case to 4WD Low position.
  26.  
  27. Position the transfer case on the dowel pins.
  28.  
  29. Rotate the transfer case output shaft until the gears engage with the output gear on the transmission. Slide the transfer case forward to the transmission.
  30.  

Be sure that the transfer case fits flush against the transmission. Severe damage will result if the transfer case bolts are tightened while the transfer case is binding.

  1. Install one attaching screw. Remove the dowel pins and install all of the remaining attaching screws.
  2.  
  3. Connect the driveshafts in the same positions from which they were removed.
  4.  
  5. Connect the speedometer cable and parking brake cable.
  6.  
  7. Fill the transfer case with the proper amount of lubricant. See General Information & Maintenance .
  8.  
  9. Lower the vehicle.
  10.  
  11. Install the transfer case lever, trim boot and lever knob.
  12.  

1976-79 Models
  1. Remove the shift lever knob, trim ring, and boot.
  2.  
  3. Remove the transmission access cover from the floorpan.
  4.  
  5. Drain the lubricant from the transfer case and transmission.
  6.  
  7. Disconnect the torque reaction bracket from the frame crossmember, if so equipped.
  8.  
  9. Support the engine and transmission by placing a jackstand under the clutch housing.
  10.  
  11. Remove the rear frame crossmember.
  12.  
  13. Mark the driveshaft yokes for reference during assembly and disconnect the front and rear driveshafts from the transfer case.
  14.  
  15. Disconnect the speedometer cable from the transfer case.
  16.  
  17. Remove the bolts attaching the transfer case to the transmission and remove the transfer case. Remove the gasket which goes between the the transmission and transmission case.
  18.  

here is one transfer case attaching bolt located at the bottom right corner of the transmission that must be removed from the front end of the case.

  1. Install the transmission-to-transfer case gasket on the transmission.
  2.  
  3. Shift the transfer case into the 4WD low position.
  4.  
  5. Install a 3 / 8 -16 x 4 in. dowel pin on each side of the transmission to assist in guiding the transfer case into place during installation.
  6.  
  7. Position the transfer case on the dowel pins and slide the case forward until it seats against the transmission. It may be necessary to rotate the transfer case output shaft until the mainshaft gear on the transmission engages the rear output shaft gear in the transfer case.
  8.  

Make sure that the transfer case is flush against the transmission. The case could be cracked if the attaching bolts are tightened while the transfer case is cocked or binding.

  1. Install two transfer case attaching bolts, but do not tighten them completely.
  2.  
  3. Remove the dowel pins and install the remaining attaching bolts, retightening them all to 30 ft. lbs.
  4.  
  5. Fill the transfer case with SAE 80W-90 gear lubricant (API GL-4).
  6.  
  7. Assemble the remaining components in the reverse order of removal.
  8.  

1980-86 Models
  1. On models with automatic transmission, remove the shift lever knob, trim ring, and boot from the transfer case shift lever.
  2.  
  3. On models with manual transmission, remove the shift lever knob, trim ring, and boot from the transmission and transfer case levers.
  4.  
  5. Remove the transmission access plate from the floor pan.
  6.  
  7. Raise and support the vehicle on jackstands.
  8.  
  9. Support the engine at the clutch housing and remove the rear crossmember.
  10.  
  11. Mark the front and rear driveshaft-to-transfer case position and disconnect them at the transfer case.
  12.  
  13. Disconnect the speedometer cable at the transfer case.
  14.  
  15. Disconnect the parking brake cable at the equalizer.
  16.  
  17. Disconnect the exhaust pipe bracket at the transfer case.
  18.  
  19. Unbolt the transfer case from the transmission and remove it.
  20.  
  21. Attach the transfer case to the transmission Torque the bolts to 30 ft. lbs.
  22.  
  23. Connect the exhaust pipe bracket at the transfer case.
  24.  
  25. Connect the parking brake cable at the equalizer.
  26.  
  27. Connect the speedometer cable at the transfer case.
  28.  
  29. Connect the front and rear driveshafts at the transfer case.
  30.  
  31. Install the rear crossmember. Torque the bolts to 30 ft. lbs.
  32.  
  33. Lower the vehicle.
  34.  
  35. Install the transmission access plate.
  36.  
  37. On models with manual transmission, install the shift lever knob, trim ring, and boot on the transmission and transfer case levers.
  38.  
  39. On models with automatic transmission, install the shift lever knob, trim ring, and boot on the transfer case shift lever.
  40.  

Some 1980-81 vehicles have experienced difficult transfer case shifting. This may be the result of the transfer case shift lever shaft being bent at the threaded end. To correct this condition, the shift lever shaft and, if necessary, the lever must be replaced. The part numbers are:



Shaft: 5360045
 
Lever w/4-cyl & SR-4, CJ-5 and CJ-7: 5360044
 
Lever w/6 or 8 & T-176, CJ-7: 5360044
 
Lever w/6-cyl & SR-4, CJ-7: 5360129To correct the condition:
 

  1. Remove the transfer case.
  2.  
  3. Remove the defective lever shaft, and lever.
  4.  
  5. Install new lever shaft and lever.
  6.  
  7. Install the transfer case.
  8.  

TRANSFER CASE SHIFT LINKAGE ADJUSTMENT



Only the Dana/Spicer 18 has adjustable linkage.

Spicer 18

This linkage should be adjusted to give 1 / 2 in. clearance between the floor pan and the lever when in four wheel drive, low range.

 
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