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Round #2

I should comment here that when we separated the case halves, not everything ended up staying in the "correct" half of the cases.  Well, I should say they didn't quite look like the did in the instructions.  This didn't really make much of a difference, since I replaced much of the parts that were on the wrong side, so to speak.  These were the replacement parts for the 2LO kit.  I just thought I would comment about it and tell you not to worry too much.  Take you time, get acquainted with what parts are where, how they slide back and forth on each other, etc.  After you do, you should be able to recognize which parts engage to give you 4 wheel drive, when 4LO is engaged, etc.....you know, a quick self-taught course on "Transfer Case 101".

Rear case section with chain drive and gears

Here is the back case section.  You can see the big ol' chain drive.  The oil pump is located across the top of the case.  The pickup screen is circled in yellow and a string of little yellow dots trace the oil tube.  Although not mentioned in the instructions, I cleaned the residue from the pickup screen.  It slides out of a grooved recess in the housing.  Don't get too carried away while cleaning it.  I didn't want to pull the other end of the tube loose.  My screen had some small metal filings on it and these where easily cleaned off with some carb cleaner.  The front and rear shafts are also labeled in the above picture.

Front case section showing the range and mode parts

The above picture shows the front case which we'll be discarding once all of the parts are stripped from it.  The mode spring, mode fork, and mode sleeve are all used again, along with the front output shaft bearing and and a few other parts that I'll get to.  After removing the mode spring, carefully pull the mode fork towards you while holding onto the mode sleeve.  The shift rail will come out also, as it is attached to the mode fork.  The mode sleeve can easily slip right out of the fork and you don't want to drop it and crack it.  Because my chain and shafts stayed in the rear case (unlike the pictures in the instructions), I did not have to bother with removing them from the front case as covered in steps 7, 8, and 9 of the instructions.

You can also see the shift sector and the range fork in the above picture.  The shift sector is turned by the shift lever (attached to your 4 wheel drive shifter).  It works on a series of cams and a slotted part that causes the mode fork (2WD or 4WD) and the range fork (HI or LO) to move into position at the appropriate times when you change the position of your shifter.  

Removing the mode spring from the shift rail

OK....on with the show.  Alan removes the mode spring.  Set it aside as you will be using it when you assemble the t-case.  (Did you see how clean this guy's hand is?  OK...you guessed it, I did most of the work and when I had to take the pictures, I used Alan as the prop for the photos!)

Closeup view of the shift sector

After you remove the range and mode forks, along with the mode sleeve, you can get a good look at the shift sector.  The red area below the shift sector is a plastic plug and is in the hole where the 4WD indicator switch is located.  My switch will be switched when I pull the t-case from Lady and install this one.  You can clearly see the slot that is cut into the shift sector.  This is what controls the range fork's movement.  The pointing tips at the top of the shift sector are the detent positions that you feel as you move your 4WD shifter in the cab.  

Since I am installing the Tera 2LO kit, I will be discard this shift sector and replacing it with a new one that has a 5th position for the 2LO range.


More of Round #2



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