Disassembly/Assembly
DISASSEMBLE1. Remove indicator switch from front case.
Fig. 35 Rear retainer:
2. Remove rear retainer bolts, rear retainer and discard retainer seal.
3. Remove upper snap ring that retains speedometer gear on shaft, then remove speedometer gear.
4. Remove lower snap ring.
5. Remove oil pump and discard oil pump seal.
6. Loosen rear case by prying corners loose to break seal.
7. Separate front and rear cases and remove oil pickup screen, tube and magnet from rear case.
8. Remove mode spring from shift rail.
Fig. 37 Removal of sprocket & drive chain:
9. Remove driven sprocket snap ring, then remove sprocket and drive chain.
10. Remove mainshaft, mode fork and shift rail as an assembly.
11. Remove front output shaft.
Fig. 38 Range fork & hub:
12. Remove range fork and hub.
13. Remove input gear bearing retainer and snap ring.
14. Remove low range gear snap ring, then low range gear and input gear as an assembly.
15. Remove input gear and thrust washer from low range gear.
16. Remove shift detent plug, O-ring, spring and plunger.
17. Remove shift sector and seals.
18. Remove synchronizer snap ring, then synchronizer sleeve and hub as an assembly.
19. Remove stop ring.
20. Remove drive sprocket from mainshaft.
ASSEMBLE
During assembly, lubricate components with Dexron II automatic transmission fluid.
1. Assemble input gear, thrust washer and low range gear as an assembly. Ensure that low range gear snap ring is fully seated.
2. Install input and low range gear assembly in front case and secure input gear with snap ring.
3. Install shift sector and new sector shaft seals. Install range lever on sector shaft and torque lever locknut to 22 ft. lbs.
4. Install range fork and hub.
5. Replace mainshaft pilot bearing as follows:
a. Remove bearing using Remover Tool MD-998346 or equivalent and two suitable size backup wrenches.
b. Install new bearing using Tool Handle C-4171, Installer 5065 and a shop press. The bearing is seated when installer tool contacts the input shaft.
6. Replace the mainshaft rear bearing as follows:
a. Remove rear retainer seal with Remover Tool C-4163 or equivalent.
b. Remove bearing with Tool Handle C-4171 and Installer C-4609 or equivalents.
c. Clean bearing bore thoroughly and install bearing with Handle C-4171 and Installer C-4609 or equivalents.
d. Install new seal in retainer.
7. Assemble mainshaft, stop ring, synchronizer and mainshaft drive sprocket.
8. Insert mode fork in synchronizer sleeve, then install mainshaft and fork as an assembly. Ensure shift rail is aligned in range fork and is seated in case bore.
9. Replace front output shaft front and rear bearings as follows:
a. Remove front bearing from front case bore with Tool Handle C-4171, Remover C-4610 or equivalents and a shop press.
b. Remove rear bearing from rear case bore with Remover Tools L-4518-1 and L-4454-1 or equivalents.
c. Clean bores thoroughly.
d. Install new front bearing with Tool C-4210, Handle C-4171 or equivalents and a shop press.
e. Install new rear bearing with Handle C-4171 and Installer C-4608 or equivalents.
10. Install drive chain and front shaft sprocket.
11. Install snap ring that secures driven sprocket to front output shaft.
12. Install detent plunger, spring and plug. Replace O-ring on plug if necessary. Torque plug to 16 ft. lbs.
13. Install mode spring on shift rail.
14. Install oil pump, pickup tube and screen in rear case.
15. Apply 1/8 inch RTV sealant to front case sealing surface.
16. Align and install rear case on front case. Torque bolts to 20-25 ft. lbs.
17. Install lower snap ring on mainshaft, then speedometer gear and upper snap ring.
18. Install new seals in retainers if necessary.
19. Apply 1/8 inch RTV sealant to sealing surface of rear retainer. Torque bolts to 23 ft. lbs.
20. Install yokes, seal washers and retaining nuts. Torque yoke nuts to 130-200 ft. lbs.
21. Install vacuum switch. Torque switch to 20 ft. lbs.
22. Fill transfer case with suitable lubricant.