Steps 1-40

Transfer Case Assemble

^ Tools Required
- J 8092 Universal Handle
- J 37668-A Seal Installer
- J 42738 Seal Installer
- J 43484 Seal Installer

Important: Do not reuse any of the retaining rings for any of the following service procedures. Use only new retaining rings.





1. Install the input shaft bearing.





2. Install the input shaft bearing retaining ring.





3. Install the front output shaft bearing.





4. Install the front output shaft bearing retaining ring.





Notice: Refer to Fastener Notice in Service Precautions.

Important: Make sure that the poppet assembly is seated correctly on the sector.

5. Install the poppet plunger assembly in the front transfer case.
^ Tighten the transfer case retaining bolt to 15 Nm (11 ft. lbs.).





6. Install the front output shaft end cap (new shaft only).





7. Install the tone wheel.
8. Install the front output shaft assembly.





9. Install the front output shaft retaining ring.





10. Install the input shaft thrust washer.





11. Install the input shaft assembly.





12. Install the input shaft second thrust washer.





Important: When installing the thrust plate in the planetary gear, make sure that the lettering is facing up.

13. Install the input shaft thrust plate.





14. Install the input shaft retaining ring.





15. Install the planetary gear assembly.





16. Install the range shift sleeve in the range fork.
17. Align the range shift sleeve on the planetary gear.





18. Align the roller on the range fork and the sector assembly.
19. Install the range shift fork.





Important: When installing the shift rail in the range fork assembly, make sure that the machined hole is facing the bottom of the front case half.

20. Install the shift rail.





21. Install the clutch lever.





Important: When performing the following service procedure, make sure that the clutch lever inserts are tightened evenly. Make sure that the clutch lever moves freely after the inserts are tightened and engaging the lever.

22. Install the clutch lever insets in the front case half.
^ Tighten the clutch lever inserts to 40 Nm (28 ft. lbs.).





Important: The following service procedure is to be performed only if the mainshaft is new.

23. Install the mainshaft oil restricter (must be flush with the end of the shaft).





24. Install the outer clutch drum bearing.





25. Install the outer clutch drum.





26. Install the inner drum.





Important: When installing the clutch spring washer on the mainshaft, make sure that the finger of the spring washer are facing up.

27. Install the clutch return spring washer (non-preload shown, preload will have a large wavy washer in Outer drum).
28. Install the retaining ring for the inner drum assembly.





29. Install the clutch backing plate in the outer drum so that the notch in the plate is facing down.





30. Install the clutch pack in the outer drum.
31. Adjust the clutch clearance.





32. Assemble the thrust bearing support plate.





33. Install the apply assembly.





34. Install the apply assembly retaining ring.





35. Align the tab on the bearing support plate with the Clutch fork.
36. Align the mainshaft teeth to the planetary gear and range fork sleeve teeth.
37. Install the mainshaft assembly.





Important: If the original drive chain and sprockets are being reused, make sure that the alignment marks that were made during the disassembly of the drive chain and sprockets are now properly aligned.

38. Install the drive chain and sprockets.





39. Install the drive sprocket retaining ring.





40. Install the driven sprocket retaining ring.