Rear Disconnect

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Tools Needed:

• ⅜ Ratchet and Socket Set
• Dead blow hammer
• 14 mm Box-end wrench
• Gasket Scraper
• Jack Stand
• Drift Punch
• Red Loctite
• Wheel Bearing Grease
• Ultra Grey™ RTV Silicone
• Transfer Case Gear Oil

Installation Notes:

1. Read all instructions completely and carefully before you begin.

2. Check to make sure the kit is complete and that no parts are missing. If anything is missing, please contact Trail-Gear at (559) 252-4950.

3. Park vehicle on a clean, dry, at, level surface and block the tires so the vehicle can not roll in either direction.

4. The installation of this kit will require modification to the frame and rear drive-line. Such modification should only be performed by a qualified technician.

5. Do not remove the rubber band from the rear disconnect tail housing assembly until you are ready to perform step 20 of the install instructions.

Vehicle Modifications:

• Shortening of rear drive-line
• Clearance or modification of rear frame cross-member.

Installation Instructions:

1. Place vehicle securely on jack stands.

2. Remove the ll plug from the transfer case and completely drain the oil from the transfer case.

3. Unbolt the rear drive-line from the transfer case output range.

4. Disconnect the speedo cable from the transfer case.



5. Lower the transfer case or remove the transfer case from the vehicle. If an aftermarket cross-member or skid plate is being used, the cross-member bolts may have to be loosened and/or the cross-member may have to be removed.

6. Remove the nut and washer connecting the rear output flange to the output shaft. Discard the nut & washer. Save the output flange for re-installation.



7. Remove the (7) bolts connecting the tail shaft housing to the transfer case. Save the (7) bolts for re-installation.



8. Remove the tail shaft housing and discard.



9. Remove any remaining gasket material from the flange of the transfer case housing.

10. Install the (4) M10 x 1.25 studs supplied with the kit into the top (4) bolt holes in the transfer case housing. Use a stud installation tool or the double nut method to make sure the studs are installed securely.



11. Install a new gasket or Ultra Grey™ compound (not included) onto the flange of the transfer case housing.



12. Install the Rear Disconnect Intermediate Housing Assembly onto the transfer case housing.



13. Loosely install (3) of the bolts removed in Step 7 into the bottom (3) bolt holes of the transfer case housing.



14. Loosely install (4) M10 x 1.25 flange nuts onto the M10 studs installed on Step 10.

15. Evenly tighten the (3) M10 bolts and the (4) M10 nuts.

16. Install the Rear Disconnect Output Gear onto the transfer case output shaft.



17. Place Red Loctite to threads of the nut.



18. Install the supplied staking nut and washer to secure the Rear Disconnect Output Gear to the transfer case output shaft.



19. Stake the nut onto the output shaft using a drift punch.



20. Apply wheel bearing grease to the roller bearing supplied with the kit and install the greased bearing over the Rear Disconnect Output Gear.



21.Remove the rubber band from the rear disconnect tail housing assembly. Carefully install the supplied gasket and Rear Disconnect Tail Housing onto the Rear Disconnect Intermediate Housing. Note: Modification or clearance of the frame cross-member will be required.



21. Continued



22. Install the (6) M10-1.25 bolts and the (6) remaining M10-1.25 flange nuts to secure the Rear Disconnect Tail Housing to the Rear Disconnect Intermediate Housing. Snug all bolts evenly before tightening.



23. Install the output flange onto the Rear Disconnect Output shaft using the supplied staking nut and washer. Red Loctite should be applied to threads of the nut. Stake the nut onto the Rear Disconnect Output Shaft using a drift punch.



24. Install one end of the 5mm air line supplied with the kit into the push fitting in the side of the Rear Disconnect Intermediate Housing.



25. Connect the other end of the 5mm air line to the ARB compressor.

26. Fill the transfer case with the appropriate grade of oil. The transfer case should be overfilled with an additional quart of oil to account for the internal volume of the Rear Disconnect.

27. Reinstall the transfer case and cross-member/skid plate back into the proper position in the vehicle.

28. Reinstall the drive-line onto the transfer case output flange. Note: The Rear Disconnect adds additional length to the transfer case housing and will require shortening or other modification of the drive-line.