Electronic Shift

Before assembly, lubricate all parts with Mercon multi-purpose automatic fluid No. E4AZ-19582-B, or equivalent.

1. If removed, start a new bearing into end of shaft ear, then position spider into bearing and press bearing into snap ring groove using U-joint tool No. T74P-4635-C or equivalent.
2. Remove tool and insert a new internal snap ring on groove.
3. Start a new bearing into opposite side of shaft ear and use U-joint tool to press bearing until opposite side contacts snap ring.
4. Remove tool and install a new internal snap ring in groove. Reposition front output shaft assembly and install the other two bearings in the same manner.
5. Check U-joint for freedom of movement. If a binding condition occurs due to misalignment during installation procedure, tap ears of both U-joints to relieve bind. Do not install front output shaft assembly if U-joint shows any signs of binding.
6. If removed, drive ball bearing into front case using ball bearing replacer No. T83T-7025-B and driver handle T80T-4000-W or equivalent. Drive ball bearing in straight, ensuring it is not cocked in bore. Install internal snap ring that retains ball bearing to the front case.
7. If removed, install front output oil seal in front case bore using output shaft seal installer No. T83T-7065-B and driver handle T80T-4000-W or equivalents.
8. If removed, install ring gear in front case. Align serrations on outside of ring gear to serrations previously cut in front case bore. Using a press, start piloted chamfered end of ring gear first and press in until it is fully seated. Ensure ring gear is not cocked in bore.
9. If removed, install ball bearing in bearing retainer bore. Drive bearing into retainer using bearing replacer No. T83T-7025-B and driver handle T80T-4000-W or equivalent. Ensure ball bearing is not cocked in bore, then install internal snap ring.
10. Install front output shaft and U-joint assembly through front case oil seal. Position ball bearing and retainer assembly over front output shaft and install in the front case bore. Ensure clip on bearing retainer aligns with slot in front case. Tap bearing retainer into place with a plastic hammer, then install external snap ring.
11. Apply stud and bearing mount No. EOAZ-19554-BA or equivalent to mounting adapter bore, and drive oil seal into bore with input shaft seal installer No. T83T-7065-A and driver handle T83T-4000-W or equivalent.
12. Slide sun gear, thrust plate and thrust washer into position on input shaft. Press ball bearing over input shaft, then install external snap ring to input shaft. Sun gear recessed face and ball bearing snap ring groove should be toward rear of transfer case. Stepped face of thrust washer should face toward ball bearing.
13. Install planetary gear to sun gear and input shaft assembly, then install internal snap ring to planetary carrier.
14. Place tanged snap ring in mounting adapter groove. Position input shaft and planetary gear set in mounting adapter and expand tanged snap ring while pushing inward until planetary assembly and input shaft assembly are seated in the adapter. When properly seated, tanged snap ring will snap into place. Check installation by holding mounting adapter by hand and tapping face of input shaft against a wooden block to ensure snap ring is engaged.
15. Ensure all traces of RTV gasket sealant are removed from front case and mounting adapter mating surfaces. Install a bead of RTV gasket sealant on surface of front case.
16. Position high-low shift fork and hub as an assembly into planetary gear set. If removed, install roller bushing assembly to high-low shift fork. Ensure nylon wear pads are installed on shift fork and that dot on pad is installed in the shift hole.
17. Place oil pump cover with word Top facing the front of front case. Install two pins (with flats facing upward) with spring between pins and place assembly in oil pump bore in output shaft. Place oil pump body and pick-up tube over shaft and make sure that pins are riding against inside of pump body. Place oil pump rear cover with words Top Rear facing the rear of front case. The word TOP on front cover and rear cover should be on the same side. Install pump retainer with tabs facing the front of the transfer case. Install four retaining bolts and rotate output shaft while tightening bolts to prevent pump from binding, then tighten bolts to 36-40 inch lbs. Prime pump through oil filter pick-up tube while turning input shaft. Output shaft must turn freely within oil pump, if binding is present, loosen four bolts and retighten.
18. Install output shaft and oil pump assembly in the input shaft. Ensure internal splines of output shaft engage internal splines of high-low shift hub. Ensure oil pump retainer and oil filter leg are in groove and notch of the front case. Install collector magnet in notch of the front case.
19. If disassembled, assemble 2W-4W lock-up assembly as follows:
a. Install tapered compression spring in lock-up with small end installed first.
b. Place lock-up hub over spring and and engage lock-up hub in notches in the lock-up collar with internal snap ring.
20. Install chain, drive sprocket and driven sprocket as an assembly over output shafts. Install thrust washer on front output shaft and install external snap ring over thrust washer to retain driven sprocket.
21. Install shift rail through high-low shift fork and ensure rail is seated in front case bore.
22. Install 2W-4W shift fork to 2W-4W lock-up assembly. If removed, ensure nylon wear pads are installed on forks. The dot on pad must line up with hole in fork. Install 2W-4W lock-up collar and hub assembly over shaft and onto shift rail. If removed, install roller bushing assembly to 2W-4W lock-up fork.

Fig. 21 Torsion Spring Installation:

23. Slide spring spacer on camshaft and position it beneath drive tang. Place torsion spring on camshaft and install as shown in Fig. 21.
24. Install tang-end of camshaft assembly on alignment pin pressed in front case. Position torsion spring tangs and camshaft tang so that they are pointing toward top side of transfer case and are touching high-low shift fork assembly.
25. Lift 2W-4W shift fork slightly while holding shift rail down and rotate helical cam track into high-low and 2W-4W fork roller bushings by turning camshaft assembly. Triangular shaft should be in two wheel high position at final assembly.
26. If disassembled, assemble shift collar hub to clutch housing and install snap ring. Install clutch housing assembly on output shaft.
27. If removed, drive caged needle bearing into rear cover bore with needle bearing replacer T83T-7127-A and driver handle T80T-4000-W or equivalents.
28. If removed, install ball bearing in rear cover bore with bearing replacer T83T-7025-B and driver handle T80T-4000-W or equivalent. Ensure ball bearing is not cocked in bore, then install internal snap ring that retains ball bearing to rear cover.
29. Install new O-rings on clutch coil assembly studs and grommet. Install clutch coil assembly from inside rear cover until wire and studs extend through cover, then install nuts and torque to 6-8 ft. lbs. Do not kink or trap wire while seating clutch coil assembly to cover.
30. Coat mating surface of front case with a silicone gasket sealant.
31. Install 2W-4W shift fork spring to shift rail and shift fork with spring mounted in a vertical position.
32. Before installing rear cover to front case proceed as follows:
a. Align output shaft with rear cover output shaft bore.
b. Align camshaft assembly with rear cover motor bore.
33. Install rear cover to front case. If difficulty is encountered with seating rear cover, tap output shaft with a sharp blow using a rubber mallet in a direction away from triangular shaft while pushing down on rear cover. Another method is to insert a screwdriver through sensor bore in rear cover so that blade of screwdriver engages slot in middle of 2W-4W shift fork and move fork toward triangular shaft to engage shift rail in rear cover bore.
34. Install bolts retaining rear cover to front case and torque at 23-30 ft. lbs.
35. Install speed sensor in its bore in the rear cover.
36. Using pliers equipped with soft jaws, rotate triangular shaft so it is aligned with triangular slot in motor. If shaft will not stay in 4H position, rotate shaft clockwise to 2H position. During motor installation, rotate motor counterclockwise until motor is aligned with mounting holes.
37. Slightly loosen two nuts that attach slotted support bracket to end of motor house. Do not loosen two nuts or studs that attach motor end cap to motor housing.
38. Apply black non-acid cure silicone rubber E7TZ-19562-A or equivalent to motor housing base and install on transfer case.
39. Install motor and three screws along with speed sensor bracket and torque to 6-8 ft. lbs.
40. Holding slotted support bracket tight against motor housing end, secure bracket to transfer case.
41. Retighten two nuts that attach slotted support bracket to end of motor.
42. Install brown clutch coil wire to center terminal, if removed install green and blue wires, then install locking sleeve.
43. If removed, position wire connector mounting bracket on rear cover, then install bolts and torque to 5-7 ft. lbs.
44. Install wire connector to mounting bracket, then install speedometer drive gear into rear cover bore.
45. Drive oil seal into rear cover bore with output shaft seal installer, T83T-7065-B and driver handle T80T-4000-W or equivalent.
46. Install rear flange on output shaft, then rubber seal, washer and nut, then torque nut to 150-180 ft. lbs.
47. Install drain plug and torque to 14-22 ft. lbs.
48. On GSB ``IRH'' option vehicles, install front yoke, rubber seal, steel washer and locknut to front output shaft, then torque nut to 150-180 ft. lbs.
49. Remove fill plug with a 3/8 drive ratchet, then fill transfer case with three pints of Mercon multi-purpose automatic transmission fluid E4AZ-19582-B or equivalent. Install fill plug and torque to 14-22 ft. lbs.