Core Return Instructions

Thank you for your purchase! Now that you’ve received your rebuilt transfer case, it’s time to return your core.

Preparing Your Core for Return

1. Unpacking the Rebuilt Transfer Case:

   • Carefully remove the rebuilt transfer case from the reusable transit box.

   • Leave the Insta-Pak in place inside the box, as it is molded to fit the transfer case.

2. Cleaning and Draining the Core:

   • Drain as much oil as possible from your core transfer case.

   • Clean off any excess grease and dirt before packing it for return.
     

Packing the Core for Shipment

1. Placement in the Box:

   • Set the core transfer case inside the transit box in the same orientation as the rebuilt one was removed.

   • Attach any core return paperwork, filled out correctly.

   • The Insta-Pak is shaped to support the bottom of the transfer case.

   • Use caution, as the transfer case is heavy—it may require two people to safely handle.

2. Protecting the Straps:

   • Reuse the cardboard that was on top of the rebuilt transfer case.

   • If no cardboard was present, add some to keep the straps clean.

   • The ratchet straps are positioned intentionally—refer to photos if needed.

Securing the Transfer Case:

• Strap down the transfer case properly.

• For NP205 models: Wrap the straps inside the shift rails.

• For shift link models: Run the strap between the transfer case and the shift link.

• Tighten the straps securely, but do not overtighten to the point of bending the box.

Closing and Sealing the Box:

• Place the lid back on and use the rubber hooks to lock it to the base.

• Use the supplied banding straps and hooks to secure the box.

• There are two short bands (for the short sides) and one long band (for the long side).

• Banding Instructions:

  1. Run one end of the strap up through the bottom of the hook.

  2. Wrap it around the spring arm.

  3. Run the end back through the bottom.

  4. Repeat on both sides.

  5. Pull tight. If you do not have a banding tool, using wide-mouth pliers can help.

Shipping the Core

1. Removing Old Labels:

   • Carefully remove all previous shipping labels and barcodes.

   • Do not remove any warning labels.

2. Choosing a Shipping Option:

   • You may use your own carrier if you secure a comparable or better shipping rate.

   • If you request a prepaid label, place it in a clear, legible spot on the box.

   • All prepaid labels are at your expense. The cost can either be charged separately or deducted from your core deposit refund.

3. Freight Shipments:

   • If you require freight services and are not a business open during standard hours (M-F), you must schedule a pickup in advance.

   • Let us know which day you or someone else will be available to load the truck.

4. Final Steps:

   • If using a drop-off carrier, take the package to your nearest location.

   • If a carrier pickup is scheduled, have the package fully prepared before the pickup date.

Thank you for following these steps to ensure a smooth core return process!