Preliminary Procedures

1. The purpose of this procedure is to obtain a proper clutch travel of 0.7-1.2 mm (0.0275-0.0472 in.) when assembled with a selective thrust washer.
2. Assemble or disassemble the internal components to the clutch pack snap ring (1). Refer to Transfer Case Assemble Transfer Case Cover, Apply Cam, and Clutch Pack Installation.

1

Transfer Case Snap Ring

2

Transfer Case Wave Spring

Tip
Temporarily remove the spring (2) for selective thrust washer measurement.

3

Transfer Case Apply Cam

4

Transfer Case Balls

5

Transfer Case Rotor Assembly

6

Transfer Case Thrust Bearing

7

Transfer Case Selective Thrust Washer

Procedure

1. Attach, screw, the DT-48553 to the input shaft until hand tight.
2. Attach the J 8001 .
3. Zero the J 8001 on the rotor assembly in the "free state" assembled position.
4. Rotate the rotor counter clockwise using moderate hand pressure until it stops. Record this measurement.
5. The ideal thrust washer selected will create the nominal clutch travel of 0.95 mm (0.0375 in.)
6. The selective thrust washer requires verification before proceeding. Remove the DT-48553 , install the selected thrust washer and re-measure the travel as performed above to obtain a clutch pack travel of 0.7-1.2 mm (0.0275-0.0472 in). Refer to Spacer and Shim Specifications for a list of available thrust washer sizes.
7. Remove the J 8001 and the DT-48553 .
8. Disassemble the components to the clutch pack retaining ring (1).
9. Assemble the internal components. Refer to Transfer Case Assemble Transfer Case Cover, Apply Cam, and Clutch Pack Installation.

Special Tools