Part 2

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)(Figure 20) onto the mainshaft (1).










3. Install the mode hub (2)(Figure 21) onto the mainshaft (1).










4. Install the mode hub (2) retaining ring (3)(Figure 22) onto the mainshaft (1).










5. Install the clutch gear (2)(Figure 23) 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)(Figure 24) 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 to 27-34 Nm (20-25 ft.lbs.).










8. Assemble and install range fork (2) and hub (1)(Figure 25). 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)(Figure 27).










13. Install detent plunger (4), spring (3), and plug (2)(Figure 28). Tighten the plug to 16-24 Nm (12-18 ft. lbs.).










14. Position the shift motor and mode sensor assembly (2)(Figure 29) onto the transfer case (1).










15. Install the bolts (3)(Figure 30) 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)(Figure 31). Guide mainshaft through the mode and range sleeves and into the input gear.

FRONT OUTPUT SHAFT AND DRIVE CHAIN










1. Install the front output shaft (2)(Figure 32) into the front output shaft front bearing.










2. Install the front output shaft bearing inner snap-ring (2)(Figure 33) onto the output shaft.
3. Install the new front output shaft seal with Seal Installer.










4. Insert front drive sprocket (3)(Figure 34) in drive chain (2).
5. Install drive chain around rear drive sprocket.
6. Position rear drive sprocket over the output shaft and lower the sprocket and chain assembly until the front sprocket is positioned over the front output shaft.
7. Align the splines in the sprockets to the splines on the output shafts and install the sprockets onto the output shafts.










8. Install front sprocket (2) retaining ring (3)(Figure 35).










9. Install rear sprocket (2) retaining ring (3)(Figure 36).










10. Insert magnet (1) in front case pocket (2)(Figure 37).

REAR CASE










1. Install the oil pick-up tube and screen into the rear case half.
2. 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.
3. Align mainshaft with the rear output shaft bearing and align shift rail with bore in rear case. Then install rear case (2)(Figure 38). Verify that the case alignment dowels correctly seat into their mating recesses.










4. Install 4-5 rear case (2) to front case (1) bolts (3)(Figure 39) 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.

5. Tighten bolts to 27-34 Nm (20-25 ft. lbs.).










6. Install rear output bearing inner snap-ring (3)(Figure 40) to output shaft (1).

OIL PUMP AND REAR EXTENSION










1. Install the oil pump (3)(Figure 41) onto the output shaft (2).










2. Engage the oil pump pick-up tube (2)(Figure 42) into the oil pump (1). Verify that the pick-up tube o-ring is on the tube and is correctly installed to the oil pump.










3. 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.
4. Install extension housing (2)(Figure 43) onto the rear case half (1).










5. Install rear extension bolts (2)(Figure 44). Tighten the bolts to 27-34 Nm (20-25 ft.lbs.).










6. Install the extension housing dust boot and seal assembly with Seal Installer (3) and Universal Handle (2)(Figure 45).










7. Install the front companion flange onto the front output shaft.
8. Install two bolts 180° apart into the front output shaft companion flange.
9. Place holder (1)(Figure 46) over the bolts (2) and against the companion flange.
10. Install a new front companion flange nut. Tighten the companion flange nut to 176-271 Nm (130-200 ft.lbs.).