Assembly

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 half.
4. Using Bearing Remover/Installer 6436 and Universal Handle C-4171, remove front output shaft bearing.
5. Start front output shaft bearing in case. Then seat bearing with Universal Handle C-4171 (3) and Bearing Remover/Installer 6953 (2).
6. Install front output shaft bearing retaining ring.




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




8. Install new bearing with Universal Handle C-4171 (1) and Bushing Installer 5066 (3).




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




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


INPUT AND PLANETARY GEAR






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




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




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


SHIFT FORKS AND MAINSHAFT






1. Lubricate 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 (2) and mode hub retainer 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 intermediate clutch shaft (1).




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




8. Install clutch shaft (2) snap-ring (1).




9. Lubricate sector shaft with transmission fluid and install shift sector (1) 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 range fork (2) and hub (1). Be sure hub is properly seated in low range gear and engaged to the input gear.
12. Align and insert range fork pin in 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 (1).


FRONT OUTPUT SHAFT AND DRIVE CHAIN






1. Install the front output shaft into the front output shaft bearing.
2. Install the front output shaft snap-ring (2) onto the output shaft (1).
3. Install the new front output shaft seal with Installer MB991168A




4. Install new o-ring (1) on detent plug (2).




NOTE: Shift the transfer case to the same range/mode position it was in when the shift motor was removed prior to installing the shift detent components.

5. Install detent plunger (4), spring (3), and plug (2). Tighten the plug to 16-24 Nm (12-18 ft. lbs.).




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




7. Install the front sprocket (1), rear sprocket (3), and chain (2) as an assembly.
8. Lower the front sprocket, rear sprocket, and chain over the front and rear output shafts simultaneously until fully seated on both splines.




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




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




11. Inspect mode fork assembly (1). Replace pads if necessary. Also check springs and slider bracket. Replace worn or damaged components.




12. Install the mode fork (2) and sleeve (3) over the shift rail (1) and mainshaft.




13. Install spring (2) onto the shift rail (1).




14. Insert magnet (1) in front case pocket (2).


OIL PUMP AND REAR CASE






Lubricate the oil pump components with transmission fluid before installation. Prime the oil pickup tube by pouring a little oil into the tube before installation.

CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft inner bearing race and will become mis-aligned if the bolts are loosened. If the transfer case failure has generated any debris which may have become trapped in the oil pump. the rear case and oil pump assembly MUST be replaced.

1. Install new o-ring in pickup tube inlet of oil pump, if necessary.
2. Insert oil pickup tube into the oil pump.
3. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into case interior.
4. Align oil pump with mainshaft and align shift rail with bore in rear case. Then install rear case and oil pump assembly (1).




5. Install rear output bearing snap-ring (3) to output shaft (1).




6. Install 4-5 rear case-to front case bolts (3) to hold rear case (1) in position. Tighten bolts snug but not to specified torque at this time.

CAUTION: Verify that shift rail, and case alignment dowels are seated before installing any bolts. Case could be cracked if shaft rail or dowels are misaligned.

7. Apply Mopar(R) Lock 'n Seal Adhesive to remainder of rear case-to-front case bolt threads and install bolts. Tighten bolts to 25-28 Nm (18-21 ft. lbs.),


SEAL BOOT AND SHIFT MOTOR ASSEMBLY






1. Install a new seal boot clamp onto the seal boot.
2. Install the seal boot (1) and clamp onto the slinger (2) hub and tighten the clamp with Crimp Tool C-4975-A.




3. Position the shift motor and mode sensor assembly onto the transfer case.
4. Install the bolts (3) to hold the shift motor and mode sensor assembly (2) to the transfer case (1). Tighten the bolts to 16-24 Nm (12-18 ft. lbs.).


REAR EXTENSION






1. Install new seal in rear extension housing seal with Seal Installer D-163 and Universal Handle C-4171. Verify that the weep hole in the rubber is oriented downward.
2. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of rear extension housing. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess could be displaced into output bearing.
3. Align and install rear extension (1) on the transfer case (2).
4. Apply Mopar(R) Silicone Sealer to threads of rear extension housing bolts. Then install and tighten bolts to 16-24 Nm (12-18 ft. lbs.) torque.