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Atlas 4sp Transfer Case



Atlas 4Sp Transfer Case Add Larger Gears
After a quality-control inspection, the case is loaded with one of the larger gears for the front drive assembly.		 Atlas 4Sp Transfer Case Front Drive Subassembly
This is the front drive subassembly before Lester installs it. Notice the square O-ring installed on the end of the casing. This seal prevents oil from seeping out of the front output housing.		 Atlas 4Sp Transfer Case Install Front Subassembly
Here, Lester installs the front subassembly in the Atlas 4SP case. This process requires careful attention to detail. Lester used his middle finger to align the large gear and bearing while he slid the front subassembly into position.
Atlas 4Sp Transfer Case Front Subassembly
Lester doesn't use latex gloves while performing his job because the process requires a sensitive touch to ensure each component fits where it's supposed to.		 Atlas 4Sp Transfer Case Main Subassembly
Next, the main subassembly is installed in the transfer case. This assembly serves as both the input shaft and rear output shaft of the Atlas 4SP. Here you can see Lester sliding in one of the 23 different bearings required on each Atlas 4SP.		 Atlas 4Sp Transfer Case Thrust Bearing
This is a photo of the thrust bearing that retains the mainshaft drive gear. Note the two small shims on either side of the drive-gear thrust bearing. These shims are ground to specific thicknesses to provide proper bearing clearance.
Atlas 4Sp Transfer Case Shift Control Assembly
Lester then installs the shift control assembly. Notice the bronze bushings used to isolate the guides from the aluminum case.		 Atlas 4Sp Transfer Case Install Shift Fork
With the shift rails penetrating halfway into the housing, each shift fork can then be installed into the transfer case.		 Atlas 4Sp Transfer Case Lower Center Cluster Gear
The center cluster gear is next. Lester explained this gear as the one that often causes injury to those who try to reassemble an Atlas II at home. Evidently, the proper technique for lowering this gear in place (shown) is not easy to figure out.
Atlas 4Sp Transfer Case Depth Mic Tool
Lester uses a depth mic tool to measure the center-cluster pin endplay. This measurement determines how much shim is required to ensure proper internal bearing clearance.		 Atlas 4Sp Transfer Case Apply Sealant
A special sealant is used between the front output shaft end cap and the aluminum case. Designed to keep oil in and impurities out, this sealant is a very important part of the assembly process.		 Atlas 4Sp Transfer Case Install Access Cover
Next, the access cover or pan is installed on the case. This pan is specially designed to aid with lubrication inside the case by keeping the oil level closer to the rotating gear, so the Atlas will "sling" the oil better, creating better circulation and lubrication.
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