Seal Kit turned up so spent the day re-assembling the transfer case
First job drive the inner seal casings of the shafts.
Nothing to fancy, just keep the punch away from the shaft surface
Drive both sides off in an even manner
Inner seal won't be used again
Install the new inner seals onto the shafts with 60mm ID pipe
Just like a bought one
Install the outer seal into the case with a hammer
If you're not confident, or a bad shot, utilise a seal intaller
Here's the clutch pack inside the NV245
These are the same friction material inside an automatic
Don't look like they need synthetic to me
However ...
They are single sided friction plates and the first one spins against the compression disc.
You can see there is a bit of wear here.
So there's a strong case for a friction additive, or synthetic oil
Brand new chain has 2mm less movement than the OEM with 150km's
Hardly worth the effort
The manual says to simply install the shift fork onto the shift hub
Took me a while to figure out
I installed the shift fork pivot shaft and shift fork into the centre case
and cable tied the damn thing into place
This enabled me to eliminate using the little people from the garden inside the box
The machined surfaces need very little sealant
Even a 2mm bead like this
Still oozes out the sides
Final seal deep inside the rear output shaft
That was a three beer job