Proper transfer case assembly

[Demon33]

I just replaced the input and output shaft seals in my transfer case. I had to open the case and remove the input gear in order to get the input shaft seal out. The output shaft seal came out using a flat blade screwdriver.

After pressing in the new seals, I reinstalled the input/drive gear but later realized that I simply dropped it in without regard to any alignment. I found the following page in the sevice manual and it indicates that there are 'mating marks' on the case and gears.

So my question is, is there any harm in simply dropping in the gear and sealing the transfer case or do I need to align the gears and case first as described in the sevice manual?

My thoughts are since the input and output gears have different tooth counts, it shouldn't matter what position I install the gears in since the gears will mesh in different positions with each rotation. Eventually with enough rotations, they will line up as if I had installed them with the mating marks in the proper position. However, if there gears had the same number of teeth (1:1 ratio) then alignment might matter more since the teeth of each gear would always mesh with same teeth of the other gear. Does this make sense?

 

[ali_viento]

I know this for more than 3 years ago but now i have this same problem , is there anyone can answer about aligning the transfer case !?

 

[JusMX141]

I've had about 5 cases completely apart- even swapped cups from one case to the next and never had a single problem.

I completely rebuilt a case that locked up back in 2007 on my buddy Jeff's 2G and it's still in use to this day on another daily-driven car. In another example Dave and I built a couple good cases out of broken cases that he happened to have...and one is still on his car to this day running 9's and trapping over 150.

 

[NHerron]

Well that's a load off. +1 to J

When I disassembled my transfer case a while back, I didn't mark anything, ASSuming there would be marks to line back up. When re installing, I could not find for the life of me ANY marks like the FSM mentioned. There was nothing worn, no contact being made, it was like the gears were made with no marks.

I installed it anyway and luckily haven't had any trouble.

 

[JackM]

There is nothing that needs to be timed in the t-case, so installing the gears in any position is fine.

 

[PieEyedPiper]

Good info. Though for the guys taking apart cases to swap the input seal, you might save your self a little work next time and just use a pick on the seals. I just did mine last week and I don't think I spent more than 5-10minutes working on it.
I got the pick to do the cam seals - since then I've used it almost as often as my 14mm.