Assembly

ASSEMBLY





1. Using a suitable pair of snap-ring pliers, expand the input gear bearing retaining ring (1) to release the bearing (2).




2. Pull up on the bearing (1) to remove it from the front case (2).
3. To install the input gear bearing, install the bearing into the front case as far as possible by hand, making sure the retaining ring groove is up. Expand the retaining ring with snap-ring pliers and push the bearing the remainder of the way into the case. Verify that the ring has engaged its groove in the bearing outer race.




4. Remove the front output shaft bearing retaining ring (1) from the front case




5. Using Universal Handle C-4171 (1) and Bearing Installer 9523 (2), remove the front output shaft bearing from the front case (3).




6. Install the front output shaft bearing into the front case half (3) using Universal Handle C-4171 (1) and Bearing Installer 9523 (2).
7. Install the front output shaft bearing retaining ring into the front case.




8. Install input gear and low range gear as an assembly (2).




9. Install input gear (1) retaining ring (2) with heavy duty snap-ring pliers.




10. Install the new input gear seal (1) into the front case (3).




11. Install the input shaft seal the remainder of the way with Universal Handle C-4171 (1) and Seal Installer 9036.
FRONT OUTPUT SHAFT






1. Install the front output shaft (1) into the bearing in the front case (2).




2. Install the retaining ring (1) onto the front output shaft (2).
3. Install the new front output shaft seal with Seal Installer MB991168A.


SHIFT COMPONENTS






1. Install the shift sector (1) into the transfer case (2).
2. Install the snap-ring that holds the shift sector to the transfer case.




3. Install the range sleeve (1) and range fork assembly into the transfer case.




4. Install the shift rail (1) into the range fork assembly (2).




5. Install the clutch lever(1) into the transfer case (2).




6. Install the clutch lever pivot bolt (1) into the transfer case (2).




7. Tighten the clutch lever pivot bolt (1) to 61 Nm (45 ft.lbs.).


DRIVE CHAIN, SPROCKETS, AND MAINSHAFT






1. Install the oil pump pick-up tube (1) into the transfer case (2).




CAUTION: Make certain that the anti-rotation tab on the clutch apply plate is located between the clutch lever pivot arms.

2. Install the mainshaft and clutch assembly (1) into the transfer case and input gear.




3. Install the mainshaft drive sprocket (1), front drive sprocket (3), and chain (2) as an assembly.




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




5. Install the front sprocket (1) retaining ring (2).


OIL PUMP AND REAR CASE






1. Install the oil pump (1) onto the output shaft (2).




2. Install a new o-ring onto the oil pump pick-up tube.
3. Engage the oil pump pick-up tube (2) to the oil pump (1).




4. Install the output shaft tone wheel (1) onto the output shaft (2).




5. Install the wave washer (1) onto the output shaft (2).




6. Install the rear output shaft bearing (1) onto the output shaft (2).




7. Install the rear output shaft bearing (3) retaining ring (2) onto the output shaft (1).




8. Apply bead of MOPAR(R) Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3 mm (0.125 inch). Do not use excessive amount of sealer as excess will be displaced into case interior.
9. Install the rear case (1) onto the front case (2).




10. Through the access hole (1) in the rear case half (2), expand the output shaft bearing retaining ring in the rear extension with a suitable pair of snap-ring pliers until the snap ring engages the groove in the bearing.




11. Install the access plug (1) in the rear case half (2).




CAUTION: If any of the aluminium cups protecting the heads of the case bolts are damaged, be sure to replace the entire bolt with the correct part through MOPAR(R). DO NOT substitute a plain bolt without the protective cup or else severe corrosion at that location could occur.

12. Install the rear case (1)-to-front case bolts (3). Tighten the bolts to 37 Nm (27 ft.lbs.).




13. Install the rear output seal (1) into the rear case half (2). Use Universal Handle C-4171 and Seal Installer D-163 to install the seal the remainder of the way.




14. Install the rear output shaft speed sensor (1) to the transfer case (2). Tighten the speed sensor to 17 Nm (12.5 ft.lbs.).


SHIFT MOTOR ASSEMBLY AND FRONT OUTPUT SHAFT BOOT






1. Install the shift motor isolator (1) onto the transfer case (2).




2. Install the shift motor and mode sensor assembly (1) onto the transfer case.




3. Install the bolts (1) holding the shift motor and mode sensor assembly (2) to the transfer case. Tighten the bolts to 23.50 Nm (17 ft.lbs.).




4. Install the front output shaft seal slinger with Oil Slinger Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft.
5. Install the front propeller shaft seal boot (1) and a new retaining clamp. Install a new seal boot retaining clamp with Axle Clamp Installer C-4975A.




6. Install the front output shaft speed sensor (1) into the front case (2). Tighten the speed sensor to 17 Nm (12.5 ft.lbs.).




7. Install the new transfer case isolator gasket (1) onto the transfer case (2).




8. Install the drain plug (1) and fill the case.