The Novak Guide to Rebuilding the Jeep / IH Dana 18 Transfer Case is here.
If you are having problems with the four-wheel drive option on your vehicle, it could be a result of a faulty transfer case or one of its components.If you rebuild your existing transfer case, you can avoid the financial burden of a costly replacement.This guide will show you how to do it.
Visit a local auto parts store or shop online for a rebuild kit that is compatible with your vehicle.Less expensive kits that claim to be rebuild kits often only include seals and gasket for the transfer case.
If you want to slide the jack stands into place beneath the vehicle, use the heavy duty floor jack.There are 2 jack stands in front and 2 in the rear.Don't try to work on the transfer case with only two wheels.
The transfer case should have a fluid drain plug or bolt on it.If you want the fluid from the transfer case to drain into the pan, open the plug.
The transfer case will need to be removed first.The front and rear drive shafts are usually included.The transfer case can be removed once these components are gone.The transfer case is heavy so be sure to use the heavy duty floor jack.
You need to remove bolts from the outer housing of the transfer case in order to open it.Remove the retaining clip from the transfer case oiler when the housing cover is off.
Remove the parts to be replaced inside the transfer case in the following order.
Remove the parts from the kit and put them in the reverse order.Don't forget to lubricate components that need it.
Attach the retainer clip back to the oiler disc.Carefully align the case housing halves and secure the two pieces with bolts.To tighten bolts, use a Torque wrench.
Roll the transfer case under the vehicle by placing it on the floor jack.A couple of friends will help you maneuver it back into the correct location.Put the case in place.
Remove the fill plug cap or bolt and fill the transfer case with the appropriate amount of transmission fluid.