Part 1

ASSEMBLY

BEARINGS AND SEALS










1. Remove the input shaft bearing snap-ring from the front case half with suitable snap-ring pliers.
2. Remove the input shaft bearing from the front case half with Bearing Remover/Installer 6953 (3) and Universal Handle C-4171 (2).










3. Install the input shaft bearing into the front case half with Bearing Cup Installer 8151 (3) inverted on Universal Handle C-4171 (2).
4. Install the input shaft bearing snap-ring into the front case half with suitable snap-ring pliers.










5. Remove the front output shaft front bearing snap-ring from the front case half.
6. Using Bearing Remover/Installer 6953 (3) and Universal Handle C-4171 (2), remove the front output shaft front bearing.










7. Start front output shaft front bearing in case. Then seat bearing with Seal Installer 8891 (2).
8. Install front output shaft bearing retaining ring.










9. Remove input gear pilot bearing by inserting a suitably sized drift (1) into the splined end of the input gear (2) and driving the bearing out with the drift and a hammer.
10. Install new pilot bearing with Pilot Bearing Installer 9035.










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










12. Install new bearing with Universal Handle C-4171 (2) and Bearing Installer 8128 (3).










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










14. Remove seal from oil pump with suitable pry tool.
15. Install new seal in oil pump with Seal Installer 7888 (2).










16. Remove the rear output shaft bearing (2) snap-ring (3) from the rear case half (1).










17. Remove the rear output shaft bearing from the rear case (1) using Seal Installer 7888 (2).










18. Install the rear output shaft bearing into the rear case (1) using Seal Installer 8152 (3) and Universal Handle C-4171 (2).
19. Install the rear output shaft bearing snap-ring into the rear case half.

INPUT AND PLANETARY GEAR










1. Lubricate gears and thrust washers with recommended transmission fluid.
2. Install bottom thrust washer (2) in low range gear planetary (1). Be sure washer tabs are properly aligned in gear notches.










3. Install input gear (1) in low range gear (2). Be sure input gear is fully seated.










4. Install remaining thrust washer (2) in low range gear and on top of input gear (1).










5. Install retainer (2) on input gear (1).










6. Install snap-ring (2).










7. 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.










8. Install snap-ring (2) to hold input/low range gear (1) into front bearing.
9. Install a new input gear oil seal with Seal Installer 9036 and Universal Handle C-4171.

SHIFT FORKS AND MAINSHAFT










1. Lubricate mainshaft splines with recommended transmission fluid.
2. Coat the interior of the drive sprocket hub with ATF+4 and install the drive sprocket drive hub (2) onto the mainshaft (1).










3. Install the mode hub (2) onto the mainshaft (1).










4. Install the mode hub (2) retaining ring (3) onto the mainshaft (1).










5. Install the clutch gear (2) onto the output shaft (1). Verify that the pointed ends of the clutch gear teeth are pointing to the front of the mainshaft.










6. 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.
7. Apply Loctite(TM) 242, or equivalent, to the threads of the sector support to replenish the factory applied patch. Install the shift sector support. Tighten the sector support with Socket 9033 to 27-34 Nm (20-25 ft.lbs.).










8. 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.
9. Align and insert range fork pin in shift sector slot.










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










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










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










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










15. Install the bolts (3) to hold the shift motor and mode sensor assembly (2) to the transfer case (1). Tighten the bolts to 16-25 Nm (12-18 ft. lbs.).










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