Part 2

ASSEMBLY


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.
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 (1) and oil pump assembly onto the front case (2).










5. Install 4-5 rear case (1)-to front case (2) bolts (3) to hold rear case 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.

6. Apply Loctite(TM) 242 to remainder of rear case-to-front case bolt threads and install bolts. Tighten bolts to 20-27 Nm (15-24 ft. lbs.).










7. Install rear output bearing (2) snap-ring (3) to output shaft (1).

SEAL BOOT AND SHIFT MOTOR ASSEMBLY

1. Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft.
2. Install a new seal boot clamp onto the seal boot.
3. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool C-4975A.









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

REAR EXTENSION










1. Install new seal in rear extension housing seal with Installer D-163 and Universal Handle C-4171.
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.