Remove the washer behind the lock nut. Remove the idler shaft lock nut. Flip upside down and using a long needle nose plier and petroleum jelly, install needle bearings. Midwest Transfer Case can Cryogenic Treat any shaft or gear. This is how they are positioned on the shaft once in the case.
Apply gasket sealer to both sides of the gasket, install the retainer and torque bolts to 20-40 ft. Note: There are 4 shims in the assembly. Start the range shift rail short one into the case from the front with detent notches up. Place the other bearing into the race. Position shift fork onto the shift rail with the long end facing inward. Then position the sliding clutch onto the fork.
Note: Try to line up the bolt holes before setting into place, you might have to use a hammer to tap it into place. Now you can lift the housing off of the shaft. Question: Howdy, looking to rebuild my transfer case, thus looking at your rebuild kits. Note: Do the same as above, just insert a few inches. Note: Check for free rotation of idler shaft. Man you've got me struggling to remember.
Note: When you remove the rails hold the shifter forks with the other hand and remove them from the case. Place the spacer on the bearing and shims. Please ask your sales representative for pricing and details. Note: Tapping on the input shaft with a small hammer will ease removal. This is the cast iron gear driven part-time unit that was mostly used in the 70's in almost every type of domestic truck.
Install oil fill plug and tighten to 25-35 ft. Do you recommend straight 90 weight gear oil as being the best thing to use? Note: Poppet retainer bolts are hollow and will break easily if over-torqued. First put the roller bearings back into the cup using petroleum jelly to hold them in place. Upon further investigation I was told they engaged the 4wd in Low and the truck would move. Roll the idler shaft assembly to the right and pull it out of the large hole. Is this transfer case one that you can provide or build or possibly recommend alternatives? Remove the lock nut from the shaft and slide yoke off.
Note: The use of a pic or small screwdriver may be necessary to pry the retainer off. In this configuration the 203 operates like more conventional transfer cases in that it's either in 2wd or 4wd and when in 4wd the power is evenly split from front to rear. Place the other 2 shims on the top of the spacer. There are 15 roller bearings in the assembly, put them in a small ziplock bag. Install new shift rail seals. Thanks Answer: From your description it sounds like the front bearing in the front output shaft is failing allowing it to pop out. Apply gasket sealer to both sides of gasket and drop assembly into place.
Note: At this point you are finished with tear down. Assembly begins with a freshly painted case. I dont mean I would run it like this all the time, just in winter weather. Lower the housing on to the shaft being careful not to lose any of the roller bearings. Model Years This information tag is located on rear of transfer case near where the driveshaft exits. Remove the 4 bolts from the input shaft seal retainer, and remove retainer from case.
Plus, you get a breakdown sheet of the transmission. Place the idler gear on top of the bearing. If you need addition technical help give Scott a call 888-824-2012 he can help you. Apply a small amount of sealer to the hole plugs and tap into place. During tear down, it is a good idea to keep the parts from each assembly together in bags. Kit includes new input gear, input bearing, input bearing snap rings and a complete seal and gasket kit.