Manual Shift

Prior to assembly, lubricate all transfer case components with Dexron II automatic transmission fluid, or equivalent.

1. Install output shaft in a soft jawed vise, then install a new bearing into end of shaft ear.
2. Install spider into bearing. Press bearing below snap ring groove using tool No. T74P-4625-C. Remove tool and install a new internal snap ring in groove.
3. Install a new bearing into opposite end of shaft ear. Press bearing until opposite bearing contacts snap ring. Remove tool and install a new internal snap ring in groove.
4. Reposition output shaft in vise and install remaining two bearings. Check U-joint for free movement. If there is any binding, tap ears of both shafts to relieve the bind.
5. Install ball bearing into front output shaft case bore using tool Nos. T83T-7024-B and T80T-4000-W or equivalent, then install internal snap ring. Make sure bearing is not cocked in the bore.
6. Install front output oil seal in front case bore.
7. Install ring gear in front case, using a press.

Fig. 15 Front Output Shaft Assembly:

8. Install ball bearing, then the internal snap ring into bearing retainer bore, Fig. 15.
9. Install front output shaft and U-joint assembly through front case seal, then install the ball bearing and retainer assembly and internal snap ring. The clip on bearing retainer must align with slot in front case, Fig. 15.
10. Install compression spring and detent plunger into bore from inside of case.
11. Install a new O-ring into second groove of shift lever shaft.
12. Install shift cam in front case with 2WH detent position over the detent plunger. While holding shift cam in position, push shift lever shaft into front case to engage shift cam, using alignment mark made during disassembly.
13. Install external clip on end of shift lever shaft.
14. Install two set screws in front case and shift cam. Torque screws to 5-7 ft. lbs. The set screw in the front case must be in first groove of shift lever shaft, and not bottomed against the shaft. Also, check that the shaft lever can be moved to all positions.

Fig. 14 Mounting Adapter Assembly:

15. Install sun gear, thrust plate, thrust washer, ball bearing and external snap ring onto input shaft, Fig. 14.
16. Install planetary gear set onto sun gear and input shaft assembly, then the internal snap ring on planetary carrier, Fig. 14.
17. Install oil seal, then the tanged snap ring into mounting adapter.
18. Install input shaft and planetary gear set in mounting adapter. Push the assembly into adapter until it is fully seated and the snap ring engages.
19. Apply a bead of RTV sealant to front case mating surface, then install mounting adapter on front case. Torque bolts to 35-40 ft. lbs.

Fig. 13 High-Low Shift Assembly, Output Shaft And Collector Magnet:

20. Install high-low shift hub into planetary gear set. Position high-low shift fork into inside track of shift cam and groove of the high-low shift hub, Fig. 13. Ensure nylon wear pads are installed on shift fork and dot on pad lines up with fork hole.
21. Install shift rail through high-low fork until rail is fully seated in front case bore, Fig. 13.
22. Install oil pump cover with Top marking facing front of front case. Install pump pins, flats facing up, with spring between pins, then install assembly in oil pump bore in output shaft.
23. Install oil pump body and pickup tube over shaft, then install oil pump rear body with Top Rear marking facing rear of front case.
24. Install oil pump retainer and attaching bolts. Torque bolts, while rotating output shaft, to 36-40 inch lbs.
25. Install output shaft and oil pump assembly in input shaft. Ensure external splines of output shaft engage internal splines of high-low shift hub and that the oil pump retainer and oil filter leg are in the groove and notch in front case.
26. Install collector magnet in front case, Fig. 13.
27. Install chain, drive sprocket and driven sprocket assembly over shafts. Install thrust washer on front output shaft, then the external snap ring over thrust washer.

Fig. 11 Shift Coller Hub And 2W-4W Lock-up And Shift Fork Assemblies.:

28. Assemble 2W-4W lock-up assembly, then install 2W-4W shift fork to 2W-4W lock-up assembly, Fig. 11. Ensure nylon wear pads are installed on shift fork and dot on pad lines up with fork hole.
29. Install 2W-4W lock-up collar and hub assembly over output shaft and into shift rail. Install shaft, bushing and external clip on 2W-4W lock-up fork.
30. Install shift collar hub on output shaft, then install caged needle bearing into rear cover using tool Nos. T83T-7127-A and T80T-4000-W, or equivalents.
31. Install ball bearing in rear cover bore using tool Nos. T83T-7025-B and T80T-4000-W, or equivalents. Make sure that bearing is not cocked in bore, then install snap ring to retain bearing in rear cover.
32. Install speedometer drive gear assembly into rear cover so that round end of speedometer gear clip faces the inside of rear cover.
33. Install oil seal in rear cover using tool Nos. T83T-7065-A and T80T-4000-W, or equivalents.
34. Install 2W-4W shift fork spring on inside boss of rear cover.
35. Apply a bead of silicone rubber sealant D6AZ-19562-A, or equivalent, to front case mating surface.
36. Position transfer case shift lever in 4H detent, then install front case on rear cover, making sure the 2W-4W shift fork spring engages shift rail. Install attaching bolts, starting with rear cover bolts, and torque to 35-40 ft. lbs.
37. Install rear yoke on output shaft with rubber seal, washer and nut. Torque nut to 120-150 ft. lbs.
38. Install four wheel drive indicator switch and torque to 8-12 ft. lbs.
39. Install breather plug and torque to 6-14 ft. lbs.
40. Install drain plug and torque to 14-22 ft. lbs.
41. Fill transfer case with 3 pints of Dexron II automatic transmission fluid, or equivalent, then install fill plug and torque to 14-22 ft. lbs.