Jeep Wagoneer/Commando/Cherokee 1957-1983 Repair Information

Transfer Case Assembly

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REMOVAL & INSTALLATION FC Series



See Figures 1 and 2

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Fig. Fig. 1: Arrows indicate where the 1 in. long bolts are installed on the FC series transmission adapter plate



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Fig. Fig. 2: Transfer case location

  1. Drain the transmission and transfer case.
  2.  
  3. Disconnect the hand brake cables at the frame-mounted lever.
  4.  
  5. Matchmark the driveshafts and the transfer case flanges, and disconnect them from the transfer case.
  6.  
  7. If so equipped, disconnect the PTO driveshaft from the transfer case.
  8.  
  9. Disconnect the speedometer cable at the transfer case.
  10.  
  11. Disconnect the shift linkage at the case.
  12.  
  13. Remove the rear cover plate or PTO mechanism from the case.
  14.  
  15. Remove the rear main drive gear from the mainshaft.
  16.  
  17. Support the transfer case with a floor jack and remove the attaching bolts.
  18.  
  19. Installation is the reverse of removal. Note that the attaching bolts are of two different lengths: three of the bolts are 1 1 / 8 " long; the other two are 1 inch long. The 1 inch bolts are installed in the lower left and right positions.
  20.  

Wagoneer and J-Series Truck with Spicer 20 or 21

  1. Remove the transfer case shift lever knob and trim boot.
  2.  
  3. Remove the transfer case shift lever.
  4.  
  5. Drain the transfer case lubricant.
  6.  

It is not necessary to drain the automatic transmission when removing the transfer case.

  1. Disconnect the torque reaction bracket from the crossmember, if so equipped.
  2.  
  3. Disconnect the front half of the parking brake from the equalizer clevis.
  4.  
  5. Disconnect the front driveshaft from the transfer case.
  6.  
  7. Disconnect the rear driveshaft at the transfer case. Slide the driveshaft yoke back and move the shaft to one side.
  8.  
  9. Disconnect the speedometer cable.
  10.  
  11. On 1962-69 models, remove the center cotter pin of the shaft linkage at the transfer case to disconnect the shift linkage.
  12.  
  13. On 1962-69 models, remove the exhaust pipe bracket bolts.
  14.  
  15. Remove the bolts attaching the transfer case to the transmission and remove the transfer case.
  16.  
  17. Remove the gasket which seals between the transmission and the transfer case.
  18.  
  19. Install the transfer case in the reverse order of removal.
  20.  

Jeepster and Commando

  1. Drain the transmission and transfer case.
  2.  

It is not necessary to drain an automatic transmission.

  1. Remove the transfer case shift lever.
  2.  
  3. Disconnect the rear driveshaft from the transfer case rear drive flange.
  4.  
  5. Disconnect the speedometer cable from the transfer case.
  6.  
  7. Disconnect the clutch control cables from the clutch cross shaft.
  8.  
  9. Disconnect the clutch control cross shaft ball joint at the frame.
  10.  
  11. Remove the front driveshaft.
  12.  
  13. Disconnect the stabilizer bracket from the transfer case.
  14.  
  15. Place a floor jack under the transfer case, unbolt it from the transmission and remove it from the truck.
  16.  
  17. Installation is the reverse of removal. On V6 vehicles, install the bearing support on the transfer case before installing the case. Always use a new transfer case-to-transmission gasket coated with sealer. During installation, rotate the transfer case output shaft until it meshes with the transmission output gear. Make sure that the transfer case fits tightly against the transmission before torquing the bolts. If there is ANY binding, torquing the bolts will cause severe damage. Torque the bolts to 28-32 ft. lb.
  18.  

1973-79 Quadra-Trac®

Complete transfer case removal is normally not required except when the front output shaft, front annular bearing, transmission output shaft seals or the transfer case (front housing) require service. To service the chain, drive sprocket, differential unit, diaphragm control system, needle bearing, thrust washer or rear output shaft, the rear half of the Quadra-Trac® transfer case can be removed, giving access to these components without removing the unit from the vehicle.

  1. Lift and support the vehicle.
  2.  
  3. Mark the front and rear output shaft yokes and universal joints to provide alignment references to be used during assembly.
  4.  
  5. Disconnect the front driveshaft rear universal joint from the transfer case front yoke.
  6.  
  7. Disconnect the rear driveshaft front universal joint from the transfer case rear yoke.
  8.  
  9. Remove the bolts that attach the exhaust pipe support bracket to the transfer case.
  10.  
  11. Mark the diaphragm control vacuum hoses, lock-out indicator switch wire and speedometer cable.
  12.  
  13. Disconnect the parking brake cable guide from the pivot on the right frame side.
  14.  
  15. Remove the two transfer case-to-transmission bolts which enter from the front side and the two that enter from the rear.
  16.  
  17. Move the transfer case assembly backward until the unit is free of the transmission output shaft and lower the assembly from the vehicle.
  18.  
  19. Remove all gasket material from the rear of the transmission and install the Quadra-Trac® unit in the reverse order of removal. Tighten the attaching bolt to 15-25 ft. lb.
  20.  

1980-83 All Models

  1. Raise and support the truck on jackstands.
  2.  
  3. Drain the lubricant from the transfer case.
  4.  
  5. Disconnect the speedometer cable and indicator wires, and disconnect the transfer case shift lever link at the operating lever.
  6.  
  7. Place a floor jack under the transmission and remove the rear cross member.
  8.  
  9. Matchmark the driveshafts at the yokes and disconnect them from the transfer case.
  10.  
  11. Disconnect the parking brake cable guide from the pivot on the right frame rail. On the NP 219 and 229, disconnect the shift motor vacuum hoses.
  12.  
  13. Disconnect the exhaust pipe support bracket from the case.
  14.  
  15. Place a floor jack or transmission jack under the transfer case and secure the case to the jack with a safety chain. THE TRANSFER CASE IS VERY HEAVY! Unbolt the transfer case from the transmission.
  16.  
  17. Pull the case rearward and out.
  18.  
  19. Installation is the reverse of removal. Make certain that no binding exists in the case-to-transmission fit, before installing the bolts. Torque the attaching bolts to 40 ft. lb.
  20.  

New Process 229

  1. Raise and support the truck on jackstands.
  2.  
  3. Drain the case.
  4.  
  5. Disconnect the speedometer cable and vent hose. Disconnect the shift lever link at the operating lever.
  6.  
  7. Support the transmission with a floor jack.
  8.  
  9. Remove the rear crossmember.
  10.  
  11. Matchmark the driveshafts and remove them.
  12.  
  13. Disconnect the shift motor vacuum hoses.
  14.  
  15. Disconnect the shift linkage at the case.
  16.  
  17. Support the transfer case with a floor jack or transmission jack and remove the attaching bolts.
  18.  
  19. Pull the case rearward and remove it.
  20.  
  21. Clean the gasket mating surfaces and use new gasket material for installation. Installation is the reverse of removal. Make certain that the case and transmission are installed without binding, before torquing the attaching bolts. Torque the bolts to 26 ft. lb.
  22.  

 
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