Electronic Shift

When removing RTV sealant from mating surfaces of case, use care not to damage these surfaces. The cases are made of magnesium and will damage easily.

Before assembling transfer case unit, lubricate all components with clean automatic transmission fluid, Dexron II or equivalent.

1. Install input shaft bearing and front output shaft bearing into case. Install snap rings retaining bearings into case.
2. Install front output shaft seal into case.
3. Install front output shaft through the lower bearing. The front output shaft is held in place in the case by the front output yoke and oil seal slinger assembly. Install front yoke assembly into output shaft. Torque locknut to 150-180 ft. lbs.
4. Press needle bearing and bronze bushing into output shaft.
5. Install ring gear into case slots and retain using large snap ring.
6. Insert input shaft and carrier assembly into case through input shaft bearing.
7. While supporting the input shaft and carrier assembly in case, install a new snap ring onto front side of the bearing. Ensure it is completely seated against input shaft snap ring groove.
8. Install upper input shaft oil seal into the case.
9. Assemble helical cam assembly by engaging one end of the spring onto shaft finger and and the other end of the spring onto cam finger. With the shaft finger secured carefully in a soft jaw vise, turn cam to wind up the spring until the fingers of the cam and shaft align, then slide cam forward to lock spring.
10. Install cam assembly vertically into case hole.
11. Assemble pump and output shaft as follows:
a. Place oil pump cover with the word Top facing the front of the front case. Install two pins (with flats facing upward) with spring between pins, then place assembly into output shaft oil pump bore.
b. Place oil pump body and pickup tube over the shaft. Ensure pins are riding against inside of pump body.
c. Place oil pump rear cover with words Top Rear facing rear of case.
d. The word Top on the front cover and rear cover should be on the same side.
e. Install pump retainer with tabs facing front of the transfer case.
f. Install four attaching bolts and rotate output shaft while tightening bolts to prevent the pump from binding. Torque bolts to 36-40 inch lbs. Lubricate assembly with clean automatic transmission fluid. The output shaft must turn freely within the oil pump. If binding occurs, loosen the four bolts and tighten again.
12. Install high/low shift hub.
13. Install high/low shift fork by engaging it with the shift hub flange and rotating until the roller is correctly engaged with lower groove of the helical cam assembly.
14. Install shift rail through the high/low fork bore and into the rail bore in the case.
15. Install output shaft and oil pump assembly into input shaft. Ensure the external splines of the output shaft engage internal splines of the high/low shift hub.
16. Ensure oil pump retainer and oil filter leg are in the groove and notch of front case. Install collector magnet into front case notch.
17. Assemble upper and lower sprockets with chain, then place them as an assembly over upper and lower output shafts. Install washer and snap ring retaining lower sprocket in position.
18. Assemble the 2W-4W lock-up assembly by installing tapered compression spring into lock-up collar with small end installed first. Place lock-up hub over the spring and compress spring while installing the internal snap ring.
19. Install lock-up assembly and shift fork over external splines of upper sprocket. Install shift rail with the clutch face facing rearward and long boss of shift rail facing forward.
20. Assemble four wheel drive return spring over shift rail and against the shift fork.
21. Place four wheel drive hub over the external splines of the output shaft.
22. Place clutch housing over output shaft splines and secure with snap ring. Ensure the snap ring is completely seated in its groove.
23. Press front output shaft inner needle bearing into cover bore.
24. Press rear output shaft bearing into cover bore.
25. Install a new shift shaft bushing and oil seal into cover.
26. Install new O-rings onto clutch coil assembly stubs and grommet. Install clutch coil assembly from inside rear cover until wire and studs extend through cover. Install the three nuts and torque to 6-8 ft. lbs.
27. Install rear output shaft oil seal into bearing retainer.
28. Coat mating surface of front case with a bead of non-acidic silicone sealer.
29. Place the cover on the case. Ensure lower output shaft, shift shaft and shift rail are aligned. Torque the twelve No. 50 Torx head attaching bolts to 22-36 ft. lbs.
30. Install rear bearing snap ring onto output shaft.
31. Place speedometer drive gear over shaft with slot aligned with drive ball hole. Then gear should go completely against snap ring. Place ball into hole and pull speedometer gear over ball. Snap retaining clip between the snap ring and speedometer gear.
32. Install speed sensor.
33. Apply a bead of non-acidic silicone sealer to rear bearing retainer face.
34. Place rear bearing retainer onto cover. Install and torque attaching bolts to 22-36 ft. lbs.
35. Install rear output shaft yoke assembly onto rear output shaft splines. Install rubber seal, flat washer and locknut. Torque locknut to 150-180 ft. lbs.
36. Using pliers, rotate triangular shift shaft so it is aligned with slot in the motor. Install motor. Torque motor attaching bolts to 6-8 ft. lbs.
37. Install wire connector mounting bracket on rear cover. Install attaching bolts. Torque bolts to 14-22 ft. lbs.
38. Fill transfer case with specified fluid, install drain plug and torque to 14-22 ft. lbs.