Housing and Cover
The transfer case housing (1) and rear extension housing (2) are produced from a high-pressure cast aluminum alloy. A number of reinforcement ribs are fitted in suitable locations to strengthen the transfer case assembly. These reinforcement ribs constitute a vital part of the cooling for the transfer case. The transfer case rear extension housing is retained to the transfer case housing with bolts (3). Two dowel pins locate the extension housing to the transfer case housing. The mating surfaces of transfer case housing and rear extension housing are sealed by a press-in-place serviceable seal.
The transfer case assembly is bolted to the transmission with four or five transfer case bolts. The sealing area between the transfer case housing and the transmission is sealed with serviceable O-ring (1). Two opposite radial seals seal the input shaft and prevent transmission and transfer case oil from mixing. If an input shaft seal failure occurs, the transmission and transfer case fluids will not mix as there is a weep hole in the transfer case housing between the two radial seals.
A transfer case vent (1) is located on the top area of the transfer case housing. The vent is mated to a remote vent hose assembly that is routed into the engine compartment. The oil drain plug (2) is magnetic. A mounting bracket retains the output end of the rear extension housing to the engine assembly.