TRANSFER CASE MAINTENANCE (M1028A1 AND M1031) (Cont).
Place transfer case (1) on wooden blocks with rear face up. Install idler gear .(80) assembly
into transfer case, with large end of idler gear facing front of transfer case. Aline bearings,
shim(s), and spacer inside idler gear with idler shaft (76) holes in transfer case. Drive in idler
shaft from large bore side of idler gear. Turn transfer case upright and install washer and new
locknut to end of idler shaft. Tighten locknut to 150 Ib.-ft, (203 N.m). Check for end play and
Ensure that Idler shaft cover (70) is installed with flat side facing front
output shaft rear opening.
Apply gasket sealing compound to 3 bolts (73). Install new gasket and idler shaft cover (70).
Install 3 bolts and tighten to 20 Ib.-ft. (27 N.m).
Install 2 new seals (98) to shift rail bores (103) with metal lips facing outward.
T A 5 0 3 4 6