Steps 1-30

Transfer Case Assemble

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

Important: The following service procedure will cover light duty, heavy duty and super duty version of this transfer cases.





1. Install the transfer case mounting studs 1.16 to 1.20 inches in height (only if damaged).





Notice: Refer to Fastener Notice in Service Precautions.

2. Install the sector shaft support and seal.
^ Tighten the sector shaft support to 34 Nm (25 ft. lbs.).





3. Install the sector shaft assembly.





4. Install the sector shaft lever.





5. Install the sector lever retaining bolt
^ Tighten the sector lever retaining bolt to 27 Nm (20 ft. lbs.)





6. Install the poppet assembly.
^ Tighten the poppet bolt to 18 Nm (13 ft. lbs.)





7. Install the input shaft bearing.
8. Install the input shaft bearing retaining ring.





9. Install the front output shaft bearing.





10. Install the front output shaft bearing retaining ring.





11. Install the front output shaft assembly.





12. Install the front output shaft retaining ring.





13. Install the first input shaft thrust washer.





14. Install the input gear in the planetary gear.





15. Install the input gear thrust washer.





16. Install the input gear thrust plate.





17. Install the input gear retaining ring.





18. Install the planetary gear assembly.





19. Install the input shaft retaining ring.





20. Install the range fork on the range sleeve.

Important: Make sure that the fork pin engages the sector slot.

21. Install the range fork and sleeve in the planetary gear.
22. Install the first retaining ring for the sprocket hub.





23. Install the sprocket hub on the mainshaft.





24. Install the synchronizer hub.





25. Install the synchronizer ring.
26. Install the synchronizer assembly retaining ring.





27. Install the shift mode fork on the synchronizer assembly.

Important: Make sure that the shift mode fork is installed with the pin side down.

28. Install the shift rail in the shift mode fork.





Important: Make sure that the clutch gear is facing the synchronizer.

29. Install the clutch gear.
30. Install the shift rail and the mainshaft assembly.