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










6. Remove input gear (2) pilot bearing by inserting a suitably sized drift (1) into the splined end of the input gear and driving the bearing out with the drift and a hammer.
7. Install new pilot bearing with Bearing Installer 8684.










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










9. Install new bearing with Universal Handle C-4171 and Bushing Installer 5066.










10. The bearing bore is chamfered at the top. Install the bearing (1) so it is flush with the lower edge of this chamfer (2).










11. Remove the rear output shaft bearing from the rear case (1) using Bearing Installer 8684 (2) and Universal Handle C-4171 (3).










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

INPUT AND PLANETARY GEAR










1. Lubricate gears (4) and thrust washers (5) with recommended transmission fluid.
2. Install first thrust washer in low range gear (5). 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 Installer 8841 and Universal Handle C-4171.

SHIFT FORKS AND MAINSHAFT










1. Lubricate mainshaft splines with recommended transmission fluid.
2. Install the mode hub (2) onto the output shaft (1).










3. Install the mode hub retaining ring (2) onto the output shaft (1).










4. Install the sprocket hub (2) onto the output shaft (1).










5. Install the clutch gear (2) onto the output shaft (1).










6. Install the drive sprocket (2) onto the output shaft (1).










7. Install the drive sprocket (3) thrust washer (2) onto the output shaft (1).










8. Install the drive sprocket (3) retaining ring (2) onto the output shaft (1).










9. Lubricate 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 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 range fork retaining ring.










14. Install mode fork and shift rail onto the mode sleeve.
15. Install the mode fork (2), sleeve (1), and shift rail (2) into the transfer case.










16. Install mainshaft (2) into the transfer case front housing (1). Guide mainshaft through the mode and range sleeves and into the input gear.










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










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