Assembly

ASSEMBLY

Lubricate transfer case components with Mopar(R) ATF +4, Automatic Transmission Fluid or petroleum jelly (where indicated) during assembly.


BEARINGS





1. Remove the front output shaft bearing retaining ring from inside the front case (1) half.
2. Using Installer 6953 and Handle C-4171, remove front output shaft bearing.
3. Start the front output shaft bearing in case. Then seat bearing with Handle C-4171 (3) and Installer 6953 (2).
4. Install the front output shaft bearing retaining ring.




5. Remove the front output shaft rear bearing with the screw and jaws from Remover L-4454 (2) and Cup 8148 (3).




6. Install the new front output shaft rear bearing (2) with Tool Handle C-4171 (1) and Installer 5066 (3).

INPUT GEAR





1. Align and install the input gear and bearing assembly (1) into the front case. Be sure that the input gear bearing is fully seated in the front case.




2. Install snap-ring (2) to hold the input gear assembly (2) into the front case.
3. Install a new input shaft oil seal with Handle C-4171 and Installer 8841.

MAINSHAFT





1. Lubricate the mainshaft splines with recommended transmission fluid.

NOTE: Replace the mode hub retainer if the legs were distorted during removal.

2. Install the mode hub retainer (1) onto the mode hub (2).




3. Install the mode hub and mode hub retainer (2) onto the differential assembly (1). Make sure the retainer is fully seated onto the differential.




4. Install the differential assembly (1) onto the mainshaft (2).




5. Install the differential snap-ring (1).




6. Install the mainshaft thrust washer (1) onto the input gear assembly (2).




7. Install the mainshaft and differential assembly (1) into the input gear (2).

FRONT OUTPUT SHAFT





1. Install the front output shaft (1) into the transfer case front case.




2. Install the front output shaft retaining ring (2) onto the output shaft (1).




3. Install the new front output shaft seal (1) into position in the transfer case bore (2).
4. Install the new front output shaft seal (1) with Installer MB991168A.




5. Install the new front output shaft seal slinger (1) into position on the output shaft (2).
6. Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft.




7. Install the seal boot (2) onto the seal slinger (3)
8. Install a new seal boot clamp onto the seal boot.
9. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool C-4975-A.

DRIVE CHAIN AND SPROCKETS





1. Install the front output shaft drive sprocket (1), the mainshaft drive sprocket (3), and the drive chain (2) as one unit.




2. Install the mainshaft drive sprocket (1) retaining ring (2).




3. Install the shift fork (1) and sleeve (2) as an assembly.




4. Install the front drive sprocket (1) retaining ring (2).

REAR CASE





1. Install the magnet in the front case pocket.
2. Support transfer case so that the rear case is facing upward.
3. Apply 3 mm (1/8 in.) wide bead of Mopar(R) Gasket Maker, or equivalent silicone adhesive sealer, to mounting flange of front case. Work sealer bead around bolt holes.
4. Install the rear case (1) onto the front case (2).
5. Install the bolts to hold the front case (2) to the rear case (1).
6. Tighten case bolts to 25-28 Nm (18-21 ft. lbs.) torque.

SHIFT MOTOR AND MODE SENSOR ASSEMBLY





1. Install the shift screw lower bearing (1) into the transfer case.




2. Make sure the bearing is installed with the tabs (1) up.




3. Install the shift screw top bearing (1) onto the shift screw (2). Make sure the bearing is installed with the tabs down.




4. Install the transfer case shift screw (1) and top bearing from the transfer case. Make sure that the shift screw is fully seated in the case. The missing tooth in the shift screw spines should be aligned with the indicator groove in the case.




5. Verify that the shift motor O-ring (2) is clean and properly positioned inside the machined O-ring groove of the shift motor (1).
6. Add high temperature grease between the shift motor assembly and the transfer case mating surface for sealing purposes.





NOTE: Verify that the missing tooth (2) in the shift motor drive spline (1)...





NOTE: ...and the transfer case drive spline (1) missing tooth (2) are aligned. It may be necessary to manually shift the transfer case if the shift motor and transfer case shaft are not aligned.




7. Position the shift motor and mode sensor assembly (1) onto the transfer case.





CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(R) 242 to replenish the lock patch material originally found on the bolts

8. Install the bolts (2) to hold the shift motor and mode sensor assembly (1) to the transfer case. Tighten the bolts to 9-14 Nm (7-10 ft.lbs.).

EXTENSION SEAL





1. Clean fluid residue from sealing surface and inspect for defects.
2. Using Installer D-163 (2) and Handle C-4171 (1), install the new seal into the rear case extension.