Housing O-Ring, Vent Assembly, Drain and Fill Plug Removal
| Callout | Component Name |
|---|
| 1 | Transfer Case O-Ring Seal |
| 2 | Transfer Case Vent Assembly Tip: Remove the vent only if damaged or blocked. |
| 3 | Transfer Case Bracket Bolts (Qty: 6) |
| 4 | Transfer Case Bracket |
| 5 | Transfer Case Heat Shield Bolts (Qty: 4) |
| 6 | Transfer Case Heat Shield |
| 7 | Transfer Case Drain Plug |
| 8 | Transfer Case Fill Plug |
CALLOUT AND COMPONENT NAME TABLE
Scheme 15
Scheme 15: Intermediate Drive Shaft Removal
| Callout | Component Name |
|---|
| 1 | Front Wheel Drive Shaft Shield |
| 2 | Front Wheel Drive Retainer |
| 3 | Front Wheel Drive Intermediate Shaft Special Tools J 25070 Heat Gun - 500-750F |
CALLOUT AND COMPONENT NAME TABLE
Scheme 16
Scheme 16: Rear Output Shaft Housing Removal
| Callout | Component Name |
|---|
| 1 | Transfer Case Rear Output Shaft Housing Bolt (Qty: 6) |
| 2 | Transfer Case Rear Output Shaft Housing Tip: Locate 2 screwdrivers or prybars to the flange area of the housing to ease removal. Special Tools J 25070 Heat Gun - 500-750F |
| 3 | Transfer Case Rear Output Shim |
| 4 | Transfer Case Rear Output Shaft Housing Seal O-Ring Tip: Discard the O-ring after removal. |
CALLOUT AND COMPONENT NAME TABLE
Scheme 17
Scheme 17: Right Transfer Case, Input and Output Drive Shaft Removal
| Callout | Component Name |
|---|
| 1 | Transfer Case Half Bolts (Qty: 11) |
| 2 | Transfer Case - Right |
| 3 | Transfer Case Seal |
| 4 | Transfer Case Input Shaft |
| 5 | Transfer Case Rear Output Drive Shaft |
| 6 | Transfer Case Half Locating Pins (Qty: 2) Remove the pins only if damaged. Inspect the case for similar damage. Refer to TRANSFER CASE CLEANING AND INSPECTION . |
CALLOUT AND COMPONENT NAME TABLE
Scheme 18
Scheme 18: Rear Output Shaft Housing Disassembly
| Callout | Component Name |
|---|
| 1 | Transfer Case Rear Output Drive Gear Nut Tip: Use a 30 mm socket or J 29873. Special Tools J-08614-A Pinion Flange Holder and Remover |
| 2 | Transfer Case Rear Output Shaft Flange Special Tools DT-48146 Press Support |
| 3 | Transfer Case Rear Output Shaft Bearing Assembly Tip: Use a press to remove the output shaft from the housing. |
| 4 | Transfer Case Rear Output Shaft Bearing Spacer |
| 5 | Transfer Case Rear Output Shaft |
| 6 | Transfer Case Rear Output Shaft Oil Slinger Tip: Remove the slinger only if damaged. Refer to REAR OUTPUT DRIVE HOUSING CLEANING AND INSPECTION . |
| 7 | Transfer Case Rear Output Shaft Seal Tip: Discard the seal after removal. |
CALLOUT AND COMPONENT NAME TABLE
Scheme 19
Scheme 19: Intermediate Drive Shaft Disassembly
| Callout | Component Name |
|---|
| 1 | Half Shaft Retainer |
| 2 | O-Ring |
| 3 | Front Wheel Drive Intermediate Shaft Bearing Retainers (Qty: 2) |
| 4 | Front Wheel Drive Intermediate Shaft Bearing Assembly Tip: Use a press, with the J 22912-B flat side up, in order to remove the bearing assembly. Special Tools J 22912-B Rear Pinion and Axle Bearing Remover |
CALLOUT AND COMPONENT NAME TABLE
Scheme 20
Scheme 20: Transfer Case Cleaning and Inspection
| Callout | Component Name |
|---|
| CAUTION: Refer to MACHINED SURFACE DAMAGE NOTICE . NOTE: Inspect all components or sub-components and perform any repair procedure necessary to fix the damage. If the damage cannot be repaired, replace the component or sub-component as indicated. Clean the left and right transfer case in cleaning solvent and air dry. |
| 1 | Transfer Case - Left and Right NOTE: Inspect for cracks, broken areas, or other damage. The transfer case assembly must be replaced if damage is found. |
| 2 | Transfer Case Rear Output Drive Housing Bore NOTE: Repair small scratches or nicks with light sanding. |
| 3 | Case Sealing Surface NOTE: Repair small scratches or nicks with a soft stone. |
| 4 | Transfer Case Bearing Races NOTE: Replace the transfer case assembly if a bearing has spun or if cracks are detected. |
| 5 | Transfer Case Thread Bolt Holes NOTE: Repair any damaged threads. |
| 6 | Transfer Case Half Locating Pin Holes |
| CAUTION |
|---|
| Refer to MACHINED SURFACE DAMAGE NOTICE . |
| NOTE |
|---|
| Inspect all components or sub-components and perform any repair procedure necessary to fix the damage. If the damage cannot be repaired, replace the component or sub-component as indicated. Clean the left and right transfer case in cleaning solvent and air dry. |
| NOTE |
|---|
| Inspect for cracks, broken areas, or other damage. The transfer case assembly must be replaced if damage is found. |
| NOTE |
|---|
| Repair small scratches or nicks with light sanding. |
| NOTE |
|---|
| Repair small scratches or nicks with a soft stone. |
| NOTE |
|---|
| Replace the transfer case assembly if a bearing has spun or if cracks are detected. |
| NOTE |
|---|
| Repair any damaged threads. |
CALLOUT AND COMPONENT NAME TABLE
Scheme 21
Scheme 21: Rear Output Drive Housing Cleaning and Inspection
| Callout | Component Name |
|---|
| Preliminary Procedures Inspect all components or sub-components and perform any repair procedure necessary to fix the damage. If the damage cannot be repaired, replace the component or sub-component as indicated. Clean all components in cleaning solvent and air dry. The transfer case rear output drive housing is not serviced. If damage cannot be repaired, the transfer case must be replaced. |
| 1 | Transfer Case Rear Output Shaft Flange Replace if flange, threaded holes, or splines are damaged. Inspect sealing surface for corrosion, excessive wear, or damage. |
| 2 | Transfer Case Rear Output Shaft Oil Slinger Tip: Replace the slinger if damaged, cracked, loose, or distorted. |
| 3 | Transfer Case Rear Output Shaft Bearing Assembly Tip: Inspect bearings for roughness, spalling, or pitting. |
| 4 | Transfer Case Rear Output Shaft Housing Inspect for cracks, broken areas, or other damage. Inspect bearing races for roughness, brinelling, or pitting. Inspect the O-ring channel for porosity or damage. Scratches or nicks in other areas may be repaired with light sanding. |
| 5 | Transfer Case Rear Output Shaft Splines Tip: Inspect for damage and press fit to flange. |
| 6 | Transfer Case Rear Output Shaft Tip: Inspect for pitting, excessive wear, or damage. |
CALLOUT AND COMPONENT NAME TABLE
Scheme 22
Scheme 22: Input Shaft Seal Replacement - Right
| Callout | Component Name |
|---|
| 1 | Transfer Case Input Shaft Seal - Right CAUTION: Do not use a screwdriver or punch to remove the seal. Using a screwdriver or punch to remove the seal may damage the aluminum housing sealing surface. Special Tools DT-48074 Input and Output Shaft Seal Installer J 8092 Driver Handle J 26941 Bushing and Bearing Remover - 3-4 in J 45124 Removal Bridge |
| CAUTION |
|---|
| Do not use a screwdriver or punch to remove the seal. Using a screwdriver or punch to remove the seal may damage the aluminum housing sealing surface. |
CALLOUT AND COMPONENT NAME TABLE
Scheme 23
Scheme 23: Input Shaft Seal Replacement - Left
| Callout | Component Name |
|---|
| 1 | Transfer Case Input Shaft Seal - Left CAUTION: Do not use a screwdriver or punch to remove the seal. Using a screwdriver or punch to remove the seal may damage the aluminum housing sealing surface. Special Tools DT-48074 Input and Output Shaft Seal Installer J 8092 Driver Handle J 26941 Bushing and Bearing Remover - 3-4 in J 45124 Removal Bridge |
| CAUTION |
|---|
| Do not use a screwdriver or punch to remove the seal. Using a screwdriver or punch to remove the seal may damage the aluminum housing sealing surface. |
CALLOUT AND COMPONENT NAME TABLE
Scheme 24
Scheme 24: Front Drive Axle Inner Shaft Seal Replacement
| Callout | Component Name |
|---|
| 1 | Front Drive Axle Intermediate Shaft Seal Assembly Tip: DT-48078 seats the seal to a specific depth. Other installation methods may set the seal to a non-functional depth. Special Tools DT-48078 Inner Drive Shaft Seal Installer J 8092 Driver Handle |
CALLOUT AND COMPONENT NAME TABLE
Scheme 25
Scheme 25: Input Shaft and Rear Output Drive Shaft Cleaning and Inspection
| Callout | Component Name |
|---|
| Preliminary Procedures Inspect all components or sub-components and perform any repair procedure necessary to fix the damage. If the damage cannot be repaired, replace the component or sub-component as indicated. Clean all components in cleaning solvent and air dry. The transfer case input shaft and transfer case rear output drive shaft is not serviced. If damage cannot be repaired, the transfer case must be replaced. |
| 1 | Transfer Case Input Shaft Gear Tip: Inspect for pitting, excessive wear, or damage. |
| 2 | Transfer Case Rear Output Drive Shaft Gear Tip: Inspect for pitting, excessive wear, or damage. |
| 3 | Transfer Case Input Shaft Bearing Assembly Tip: Inspect bearings for roughness, spalling, or pitting. |
| 4 | Transfer Case Rear Output Drive Shaft Bearing Assembly Tip: Inspect bearings for roughness, spalling, or pitting. |
CALLOUT AND COMPONENT NAME TABLE
Scheme 26
Scheme 26: Intermediate Drive Shaft Assembly
| Callout | Component Name |
|---|
| 1 | Front Wheel Drive Intermediate Shaft |
| 2 | Front Wheel Drive Intermediate Shaft Bearing Retainers (Qty: 2) |
| 3 | Front Wheel Drive Intermediate Shaft Bearing Assembly Tip: Use a press, with the J 22912-B flat side up, in order to install the bearing assembly. Special Tools J 22912-B Rear Pinion and Axle Bearing Remover |
| 4 | O-Ring |
| 5 | Half Shaft Retainer |
CALLOUT AND COMPONENT NAME TABLE
Scheme 27
Scheme 27: Rear Output Shaft Housing Assembly
| Callout | Component Name |
|---|
| 1 | Transfer Case Rear Output Shaft |
| 2 | Transfer Case Rear Output Shaft Bearing Spacer |
| 3 | Transfer Case Rear Output Shaft Housing |
| 4 | Transfer Case Rear Output Shaft Bearing Assembly Tip: Use a press with the J 5590 to install the housing and bearings to the output shaft. Special Tools J 5590 Pinion Bearing Race Installer - Rear |
| 5 | Transfer Case Rear Output Shaft Seal Tip: Use a press with the DT-48075 to install the seal. Special Tools DT-48075 Output Shaft Seal Installer |
CALLOUT AND COMPONENT NAME TABLE
Scheme 28
Scheme 28: Output Flange Installation
| Callout | Component Name |
|---|
| CAUTION: Refer to FASTENER NOTICE . Fastener Tightening Specifications: Refer to FASTENER TIGHTENING SPECIFICATIONS - TRANSFER CASE - GETRAG 760 . |
| 1 | Transfer Case Rear Output Shaft Oil Slinger Tip: Use a press with the DT-48077 in order to install the slinger. Special Tools DT-48077 Output Shaft Slinger Installer |
| 2 | Transfer Case Rear Output Shaft Flange Tip: Use a press with the J 5590 to install the flange. Special Tools J 5590 Pinion Bearing Race Installer - Rear |
| 3 | Transfer Case Rear Output Shaft Nut Tip: Use a 30 mm socket or J 29873. Tightening torque 235 N.m (173 lb ft) Special Tools J-08614-A Pinion Flange Holder and Remover |
| CAUTION |
|---|
| Refer to FASTENER NOTICE . |
CALLOUT AND COMPONENT NAME TABLE
Scheme 29
Scheme 29: Right Transfer Case, Input Shaft, and Output Drive Shaft Installation
| Callout | Component Name |
|---|
| CAUTION: Refer to FASTENER NOTICE . Fastener Tightening Specifications: Refer to FASTENER TIGHTENING SPECIFICATIONS - TRANSFER CASE - GETRAG 760 . |
| 1 | Transfer Case Half Locating Pins |
| 2 | Transfer Case Rear Output Drive Shaft |
| 3 | Transfer Case Input Shaft Tip: Install the input and output shafts as a set with the splines engaged. |
| 4 | Transfer Case Seal |
| 5 | Transfer Case - Right |
| 6 | Transfer Case Half Bolts (Qty: 11) Tightening torque 29 N.m (21 lb ft) |
| CAUTION |
|---|
| Refer to FASTENER NOTICE . |
CALLOUT AND COMPONENT NAME TABLE
Scheme 30
Scheme 30: Rear Output Shaft Housing Installation
| Callout | Component Name |
|---|
| CAUTION: Refer to FASTENER NOTICE . Fastener Tightening Specifications: Refer to FASTENER TIGHTENING SPECIFICATIONS - TRANSFER CASE - GETRAG 760 . |
| 1 | Transfer Case Rear Output Shaft Housing Seal O-Ring |
| 2 | Transfer Case Rear Output Shim |
| 3 | Transfer Case Rear Output Shaft Housing CAUTION: Do not use a drive hammer when the splines are not engaged. Use of a drive hammer when the splines are not engaged will damage the output shaft teeth. Use of a heat gun allows easy alignment of the bolt holes to the housing during assembly. Rotate the pinion gear during assembly to engage the gear teeth. Special Tools J 25070 Heat Gun - 500-750F |
| 4 | Transfer Case Rear Output Shaft Housing Bolts (Qty: 6) Tightening torque 29 N.m (21 lb ft) |
| CAUTION |
|---|
| Refer to FASTENER NOTICE . |
| CAUTION |
|---|
| Do not use a drive hammer when the splines are not engaged. Use of a drive hammer when the splines are not engaged will damage the output shaft teeth. |
CALLOUT AND COMPONENT NAME TABLE
Scheme 31
Scheme 31: Intermediate Drive Shaft Installation
| Callout | Component Name |
|---|
| 1 | Front Wheel Drive Intermediate Shaft CAUTION: DT-48094 must be used over the intermediate shaft prior to installation in order to protect the intermediate shaft seal from damage. Special Tools DT-48094 Inner Drive Shaft Seal Protector J 25070 Heat Gun - 500-750F |
| 2 | Front Wheel Drive Retainer |
| 3 | Front Wheel Drive Shaft Shield Special Tools DT-48076 Rock Guard Installer |
| CAUTION |
|---|
| DT-48094 must be used over the intermediate shaft prior to installation in order to protect the intermediate shaft seal from damage. |
CALLOUT AND COMPONENT NAME TABLE
Scheme 32
Scheme 32: Housing O-Ring, Vent Assembly, Drain and Fill Plug Installation
| Callout | Component Name |
|---|
| CAUTION: Refer to FASTENER NOTICE . Fastener Tightening Specifications: Refer to FASTENER TIGHTENING SPECIFICATIONS - TRANSFER CASE - GETRAG 760 . |
| 1 | Transfer Case O-Ring Seal |
| 2 | Transfer Case Vent Assembly Tip: Replace the vent if damaged or blocked. |
| 3 | Drain Plug Tightening torque 39 N.m (29 lb ft) |
| 4 | Fill Plug Tightening torque 39 N.m (29 lb ft) |
| 5 | Transfer Case Heat Shield |
| 6 | Transfer Case Heat Shield Bolts (Qty: 4) Tightening torque 11 N.m (97 lb in) |
| 7 | Transfer Case Bracket |
| 8 | Transfer Case Bracket Bolts (Qty: 2) Tip: Tighten the bracket bolts to light assembly torque. Tighten to specification after the transfer case is mounted in the vehicle. Refer to FASTENER TIGHTENING SPECIFICATIONS - TRANSFER CASE - GETRAG 760 . |
| CAUTION |
|---|
| Refer to FASTENER NOTICE . |
CALLOUT AND COMPONENT NAME TABLE
| Application | Specification |
|---|
| Metric | English |
| Transfer Case Bracket-to-Engine Bolt - Hole 4 | 50 N.m | 37 lb ft |
| Transfer Case Bracket-to-Engine Bolts - Holes 1, 2, and 3 | 23 N.m | 17 lb ft |
| Transfer Case Bracket-to-Transfer Case Bolts - Holes 5 and 6 | 50 N.m | 37 lb ft |
| Transfer Case Drain Plug | 39 N.m | 29 lb ft |
| Transfer Case Fill Plug | 39 N.m | 29 lb ft |
| Transfer Case Half Bolts (Quantity: 11) | 29 N.m | 21 lb ft |
| Transfer Case Heat Shield Bolts (Quantity: 4) | 11 N.m | 97 lb in |
| Transfer Case Rear Output Drive Gear Nut (Quantity: 1) | 235 N.m | 173 lb ft |
| Transfer Case Rear Output Drive Shaft Housing Bolts (Quantity: 6) | 29 N.m | 21 lb ft |
FASTENER TIGHTENING SPECIFICATIONS - TRANSFER CASE - GETRAG 760
