Assembly

During assembly, lubricate all transfer case components with clean Dexron II type automatic transmission fluid.

1. Replace output shaft front bearing and seal as follows:
a. Remove shaft oil seal and bearing snap ring from front case.
b. Carefully tap bearing out of case using a plastic mallet.
c. Install new bearing using tool Nos. J-8092 and J-33833, or equivalents.
d. Install bearing snap ring, then the seal using tool No. J-33834, or equivalent.
2. Remove input gear bearing as follows:
a. Remove bearing from front case using tool No. J-29170, or equivalent, and a suitable press.
b. Position snap ring on new bearing, then install the bearing using suitable removal tool and a block of wood. Install bearing until snap ring seats against case.
3. Replace input gear pilot bearing as follows:
a. Remove pilot bearing using tool No. J-29369-1, or equivalent, and a suitable slide hammer.
b. Install new bearing using tool Nos. J-8092 and J-33829, or equivalents.
4. Install input gear thrust washers, input gear, retainer and snap ring into low range gear. Ensure snap ring fully seats in groove in gear.
5. Start input gear shaft into bearing in front case, then press the gear shaft into front bearing using tool No. J-33829, or equivalent, and a suitable press. Do not press against end surface of low range gear.
6. Install new input gear snap ring into case.
7. Install new front bearing retainer oil seal using tool No. J-33831, or equivalent.
8. Apply a 1/8 inch wide bead of RTV sealer to front bearing retainer sealing surface, then install the retainer on front case. Tighten retainer attaching bolts to specifications.
9. Install new sector shaft O-ring and bushing into case bore, then position range sector in case.
10. Install range lever on range sector shaft. Tighten lever attaching nut to specifications.
11. Install detent plunger, spring and plug into case.
12. Install new pads and shift rail bushings into range fork.
13. Install range fork and shift hub assembly into case. Ensure range fork pin is properly engaged in sector shaft.
14. Replace drive sprocket bearings as follows:
a. Simultaneously press both bearings out of sprocket using tool No. J-29170, or equivalent, and a suitable press.
b. Install front bearing (A) using removal tool and a suitable press until bearing is flush with edge of bore.

Drive Sprocket Bearing Installation:

c. Install rear bearing (B) using removal tool and a suitable press until bearing is 11/64 inch below edge of bore. If bearings are pressed in any further than specified, the mainshaft oil feed hole may be blocked.
15. Install struts and spring into synchronizer hub.
16. Lubricate drive sprocket bearings, then install sprocket on mainshaft.
17. Slide synchronizer hub onto mainshaft, ensuring hub struts are properly seated in stop ring lugs.
18. Install new synchronizer hub snap ring.
19. Install synchronizer sleeve on hub, ensuring beveled spline end of sleeve faces stop ring.
20. Install new pads on mode fork, if necessary.
21. Engage mode fork in synchronizer sleeve, then install fork and rail and mainshaft assembly into case. Ensure mode fork shaft rail is properly seated in both range fork bushings.
22. Install output shaft and drive chain assembly, lifting mainshaft as necessary.
23. Install mode spring on shift rail.
24. Replace output shaft rear bearing as follows:
a. Remove bearing using tool No. J-29369-2, or equivalent, and a suitable slide hammer.
b. Install bearing using tool Nos. J-33826 and J-8092, or equivalents.
25. Assemble oil pump as follows:
a. Lubricate oil pump gears, then position gears in pump housing.
b. Align pump housing halves, then join the halves and tighten attaching screws to specifications
c. Install new pickup tube O-ring in oil pump.
26. Slide oil pickup tube into oil pump, then connect screen and hose to the tube.
27. Install oil pump, pickup tube and screen assembly into rear case. Ensure screen is properly seated in case slot.
28. Install magnet in front case.
29. Apply a 1/8 inch wide bead of RTV sealer to front case sealing surface, then install front case to rear case, ensuring dowels and mainshaft splines are properly mated. Tighten attaching bolts to specifications. A washer must be installed under each bolt at the case dowel locations.
30. Replace rear bearing as follows:
a. Tap bearing out of rear retainer using a hammer and brass drift.
b. Install bearing using tool Nos. J-33833 and J-8092, or equivalents.
31. Apply a 1/8 inch wide bead of RTV sealer to rear retainer sealing surface.
32. Position locating dowel, if previously removed, in rear retainer, then install the retainer. Tighten to specifications.
33. Install new rear retainer snap ring, ensuring it seats fully in shaft groove.
34. Replace extension housing bushing as follows:
a. Remove rear extension housing seal.
b. Remove extension housing bushing using tool Nos. J-8092 and J-33839, or equivalents.
c. Install new bushing using tool Nos. J-8092 and J-33826, or equivalents.
d. Install new seal using tool No. J-33834, or equivalent.
35. Apply a 1/8 inch wide bead of RTV sealer to extension housing sealing surface, then install the housing. Tighten to specifications.
36. Install front yoke with a new washer and nut. Tighten to specifications.
37. Install vacuum switch, using a new gasket.
38. Install drain plug and tighten to specifications.
39. Add specified quantity of Dexron II type automatic transmission fluid to transfer case, then install fill plug and tighten to specifications.