Spicer 791 Transfer Case Manual

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Spicer 791 Transfer Case Manual, page by page

Every page of this manual is shown below in order, so you can read it right here without opening the PDF. Need a part you see on these pages? Call (877) 776-4600 or Ask an Expert with the page number and we will quote it.

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Spicer 791 Transfer Case Manual page 2: Transfer Case — Page 2 of 51

Spicer 791 Transfer Case Manual page 3: Ball bearing mounted gears and — Page 3 of 51

Spicer 791 Transfer Case Manual page 4: Model Number — Page 4 of 51

Spicer 791 Transfer Case Manual page 5: 738 Transfer Case — Page 5 of 51

Spicer 791 Transfer Case Manual page 6: 738 Transfer Case — Page 6 of 51

Spicer 791 Transfer Case Manual page 7: Disconnects For Spicer — Page 7 of 51

Spicer 791 Transfer Case Manual page 8: To insure proper lubrication and operating tem — Page 8 of 51

Spicer 791 Transfer Case Manual page 9: Early Design — Page 9 of 51

Spicer 791 Transfer Case Manual page 10: EARLY DESIGN OUTPUT with DISCONNECT — Page 10 of 51

Spicer 791 Transfer Case Manual page 11: Late Design — Page 11 of 51

Spicer 791 Transfer Case Manual page 12: LATE DESIGN OUTPUT with DISCONNECT — Page 12 of 51

Spicer 791 Transfer Case Manual page 13: Transfer Case — Page 13 of 51

Spicer 791 Transfer Case Manual page 14: Transfer Case — Page 14 of 51

Spicer 791 Transfer Case Manual page 15: Transfer Case — Page 15 of 51

Spicer 791 Transfer Case Manual page 16: Transfer Case — Page 16 of 51

Spicer 791 Transfer Case Manual page 17: Transfer Case — Page 17 of 51

Spicer 791 Transfer Case Manual page 18: Transfer Case — Page 18 of 51

Spicer 791 Transfer Case Manual page 19: General Precautions for Disassembly — Page 19 of 51

Spicer 791 Transfer Case Manual page 20: Preparation for Disassembly — Page 20 of 51

Spicer 791 Transfer Case Manual page 21: Lubrication Pump — Page 21 of 51

Spicer 791 Transfer Case Manual page 22: Disassembly of Air Engaged-Spring Disengaged Shift Unit — Page 22 of 51

Spicer 791 Transfer Case Manual page 23: 7. Remove piston from shift fork shaft. — Page 23 of 51

Spicer 791 Transfer Case Manual page 24: Late Design — Page 24 of 51

Spicer 791 Transfer Case Manual page 25: 7. Remove locknut and brass washer from shift — Page 25 of 51

Spicer 791 Transfer Case Manual page 26: 13. Use a common screwdriver to remove set — Page 26 of 51

Spicer 791 Transfer Case Manual page 27: 20. Use a driver and soft hammer to remove — Page 27 of 51

Spicer 791 Transfer Case Manual page 28: Upper Shaft Disassembly without Shift Unit — Page 28 of 51

Spicer 791 Transfer Case Manual page 29: 5. Remove fourteen (14) bolts and lockwashers — Page 29 of 51

Spicer 791 Transfer Case Manual page 30: Upper Shaft Disassembly with Shift Unit — Page 30 of 51

Spicer 791 Transfer Case Manual page 31: Intermediate Shaft Disassembly — Page 31 of 51

Spicer 791 Transfer Case Manual page 32: Lower Shaft Disassembly — Page 32 of 51

Spicer 791 Transfer Case Manual page 33: 5. Using driver, remove output shaft. — Page 33 of 51

Spicer 791 Transfer Case Manual page 34: General Precautions for Assembly — Page 34 of 51

Spicer 791 Transfer Case Manual page 35: Lower Shaft Assembly — Page 35 of 51

Spicer 791 Transfer Case Manual page 36: 5. Place bearing cap onto housing. Make sure — Page 36 of 51

Spicer 791 Transfer Case Manual page 37: Upper Shaft Assembly without Shift Unit — Page 37 of 51

Spicer 791 Transfer Case Manual page 38: 5. Assemble bearing cap to housing. Secure in — Page 38 of 51

Spicer 791 Transfer Case Manual page 39: 12. Secure with eight (8) bolts and lockwashers. — Page 39 of 51

Spicer 791 Transfer Case Manual page 40: Upper Shaft Assembly with Shift Unit — Page 40 of 51

Spicer 791 Transfer Case Manual page 41: 8. Position new gasket onto the housing and in — Page 41 of 51

Spicer 791 Transfer Case Manual page 42: Assembly of Air Engaged- Spring Disengaged Shift Unit — Page 42 of 51

Spicer 791 Transfer Case Manual page 43: 5. Install setscrew into shift fork. Screw in until — Page 43 of 51

Spicer 791 Transfer Case Manual page 44: 12. Secure in place with washer and locknut. — Page 44 of 51

Spicer 791 Transfer Case Manual page 45: 19. Install drain plug. — Page 45 of 51

Spicer 791 Transfer Case Manual page 46: Late Design — Page 46 of 51

Spicer 791 Transfer Case Manual page 47: 5. Partially install set screw into shift fork. — Page 47 of 51

Spicer 791 Transfer Case Manual page 48: 15. Place air cylinder gasket onto disconnect — Page 48 of 51

Spicer 791 Transfer Case Manual page 49: 18. Position gasket onto transfer case housing. — Page 49 of 51

Spicer 791 Transfer Case Manual page 50: Lubrication Pump — Page 50 of 51

Spicer 791 Transfer Case Manual page 51: Identification Of Lube Pump Rotation — Page 51 of 51

This Spicer Parts Manual covering the 791 transfer case covers the shafts, gear sets, housings and service parts for your transfer case, with exploded diagrams and OEM part numbers.

Models covered	791
Transfer case type	Spicer transfer case
Document	Parts Manual (Spicer)
Length	51 pages
Format	PDF — free download

What’s inside

Input, output & idler shaft assemblies
Gear sets & ratio components
Case halves, covers & housings
Shift mechanism & air-control parts
Bearing, seal & gasket kits
Power-take-off & split-shaft components (where fitted)
Exploded diagrams with OEM part numbers

Spicer parts & units we stock

Pro Gear and Transmission stocks new, remanufactured and good-used parts for Spicer transfer case units:

Not sure exactly which unit you have? Check our identification guides, or Ask an Expert — send us photos of your data tag and our drivetrain specialists will identify the unit and the exact parts you need. Or call (877) 776-4600.