Figure 33. Place the Intermediate Gear in the case on the other gearsets, and slowly roll it down into place. Use your fingers to help keep the thrust washers from sliding off as the gear gets lowered. This is why the case was notched, this gear is much larger than stock and would not have been able to roll in without it. Once the shaft is down far enough, carefully start the shaft into the case. Keep the notch for the retaining washer square with the bolt hole for it, as you will not be able to turn it once it is driven in. Use a large deadblow hammer to drive the shaft into place. Use a small application of silicone in the bore on the input shaft side to prevent future leaks. Once the shaft is driven in as far as you can, insert the square retaining washer and bolt. We replaced the original bolt with a socket head screw, they look much better, and do not do as much damage to the other components as the hex head screws.
Figure 34. The case can now be sealed up. We used a TDS billet aluminum cover. This cover adds strength and rigidity to the transfer case. Put silicone on the sealing face of the case, then install the cover, torque the cover bolts to 27ft lbs.
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