Wagoneer L6-258 4.2L VIN C 2-bbl (1982)
Fluid Pump: Service and Repair
MODEL 208 TRANSFER CASE
1. Raise and support vehicle.
2. Remove fill and drain plugs and drain oil from transfer case.
3. Scribe alignment marks on propeller shaft and transfer case yoke for proper assembly, then disconnect propeller shaft.
4. Using suitable tools, remove and discard transfer case yoke retaining nut and yoke seal washer.
5. Remove yoke, using suitable tools as necessary.
6. Remove speedometer driven gear sleeve and driven gear from rear retainer.
7. Scribe alignment marks on rear retainer for proper assembly, then remove retainer attaching bolts and the retainer. Do not attempt to pry retainer
off rear case. Tap retainer loose using only a rawhide or plastic mallet.
8. Remove speedometer drive gear, then the pump housing from retainer and seal from housing.
9. When replacing bearing or retainer, remove bearing retaining snap ring from rear retainer, and tap bearing out of retainer.
10. Remove oil pump from mainshaft, then remove output shaft seal.
11. Install oil pump on mainshaft, the seal into pump housing and the speedometer driven gear.
12. Install rear output bearing in rear retainer and install snap ring, ensuring that shielded side of bearing faces interior of transfer case.
13. Install pump housing in rear retainer, then apply suitable sealant to rear retainer mating surface and install retainer on case.
14. Install retainer attaching bolts, torquing to 23 ft. lbs., and install output shaft seal, then install yoke, yoke seal washer and yoke nut, torquing nut to
120 ft. lbs.
15. Install speedometer driven gear and sleeve, then the drain plug.
16. Fill transfer case to edge of fill plug with suitable lubricant, then install fill plug.
17. Contact propeller shaft, torquing clamp strap bolts to 14 ft. lbs.
