Part 1

ASSEMBLY

BEARINGS AND SEALS










1. Remove the input shaft bearing (1) from the front case (2) with suitable snap-ring pliers.
2. Transfer the retaining ring to the new bearing if necessary and install the bearing into the front case.










3. Remove the front output shaft bearing retaining ring from inside the front case (1) half.
4. Using Installer 6436 and Handle C-4171, remove front output shaft bearing.
5. Start the front output shaft bearing in case. Then seat bearing with Handle C-4171 (3) and Installer 6953 (2).
6. Install the front output shaft bearing retaining ring.










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










8. Install the new bearing with Tool Handle C-4171 (1) and Installer 5066 (2).










9. Remove the rear output shaft bearing from the rear case using Installer 5065 (2) and Handle C-4171 (1).










10. Install the rear output shaft bearing into the rear case (1) using Remover/Installer 6953 (2) and Handle C-4171 (3).

INPUT AND PLANETARY GEAR










1. Lubricate the gears (3, 4) and thrust washers (5) with recommended transmission fluid.
2. Install the first thrust washer (5) in low range gear (4). Be sure washer tabs are properly aligned in gear notches.
3. Install the input gear (3) in low range gear (4). Be sure input gear is fully seated.
4. Install the remaining thrust washer (5) in low range gear (4) and on top of input gear (3). Be sure washer tabs are properly aligned in gear notches.
5. Install the retainer (2) on input gear (3) and install snap-ring (1).










6. Align and install the low range/input gear assembly (2) in front case (1). Be sure the low range gear pinions are engaged in the annulus gear and that the input gear shaft is fully seated in the front bearing.










7. Install the snap-ring (2) to hold input/low range gear (1) into the front bearing.
8. Install a new input gear seal using Installer 8841 and Handle C-4171.

SHIFT FORKS AND 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.










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










6. Install the intermediate clutch shaft (1).










7. Install the clutch shaft thrust ring (1).










8. Install the clutch shaft snap-ring (1).










9. Lubricate the sector shaft (1) with transmission fluid and install shift sector in case. Position slot in sector so it will be aligned with shift fork pin when shift forks are installed.
10. Install the shift sector o-ring.










11. Assemble and install the range fork (2) and hub (1). Be sure the hub is properly seated in the low range gear and engaged to the input gear.
12. Align and insert the range fork pin in the shift sector slot.










13. Install the shift rail (1) into the range fork assembly (2) and the front case.










14. Install the mainshaft and differential assembly (2) into the input gear and transfer case front case (1).