18-3. TRANSFER CASE REPAIR (Model 218) (Cont'd)
Install planetary assembly (1) until seated on input gear (4), and position range fork lug (2) into
detent slot in range sector (3).
Install two O-rings (7) on oil cooler manifolds (6) and position oil cooler (5) in front case (10).
Do not over-torque retaining nuts, or internal damage to the
transfer case oil cooler may result.
Install two washers (8) and nuts (9) securing oil cooler (5) to front case (10), ensuring narrow side of
washers (8) is next to nuts (9). Hold the end of the oil cooler stationary and use a pound-inch torque
wrench to tighten nuts (9) to 192-216 lb-in. (22-24 Nm).
Oil in case bore may prevent shift rail from seating completely
and prevent rear case installation.
Remove all traces of oil from shift rail bore in front case (10).
Tapered end of shift rail must point up.
Install shift rail (11) through range fork (12) and into shift rail bore in front case (10). Be sure shift
rail (11) is seated.