Assembly

Assembly





1. CAUTION: Do not crash the seal.

Using the special tool, install the electric shift motor seal, if equipped.





2. CAUTION: Do not crush the seal.

Using the special tool, install the shift lever seal, if equipped.





3. Install the shift lever (from outside of case), shift cam, detent spring and detent roller, if equipped.





4. NOTE: Access the shift lever set screw through the 4WD indicator switch hole, if equipped.

Tighten the shift lever set screw.





5. Using a suitable press and the special tools, install the front output shaft bearing.





6. Using the special tool, install the front yoke to flange seal.





7. Install the dust shield, if removed.





8. Install the front output shaft.
1 Position the front output shaft.
2 Install the front output shaft snap ring.





9. Using a press and a suitable bearing installer, install the front planet carrier bearing. Install the front planet carrier bearing snap ring.
10. Install the ring gear.
- Position the ring gear.
- Install the ring gear snap ring.





11. CAUTION: Do not crash the needle bearings. If removed, using a suitable press and the special tool.

Install the needle bearing and bushing into the front planet carrier.





12. Install the front planet carrier.
1 Position the front planet carrier.
2 Install the front planet carrier snap ring.





13. Using the special tools, install the input sea].





14. Install the electric shift cam assembly, if equipped.





15. Install the shift fork and the reduction hub.





16. Install the shift rail.





17. Install the oil pump and the output shaft.





18. Install the magnet into its slot in the case.





19. Install the drive chain and sprocket assembly.





20. Install the spacer.





21. NOTE: If the lockup hub assembly was disassembled, carry out the following steps.

Assemble the lockup hub assembly.
1 Position the lockup collar.
2 Install the lockup collar springs.
3 Install the lockup hub.
4 Install the armature.
5 Install the lockup hub snap ring.





22. Install the lockup hub and the shift fork and spring.





23. Install the coil housing.





24. Install the snap ring.





25. Using the special tool, install the rear output shaft bearing.





26. Using the special tool, install the front output shaft bearing.





27. install the coil.
1 Position the coil.
2 Install the nuts.

28. CAUTION: If too much silicone rubber is used when sealing the cover to the case, the excess sealant can plug the fluid filter and cause case failure.

Coat the mating surfaces of the case and cover with a small bead of sealant.





29. Position the two transfer case halves and tighten the bolts according to sequence shown.





30. Install the rear output shaft snap ring.
- Lift up on the output shaft while installing the snap ring.





31. NOTE: Place the speed sensor tone wheel into a suitable gear and bearing heater. Heat the tone wheel to 425T.

Install the speed sensor tone wheel, if equipped.
1 Install the tone wheel spacer clip against the snap ring-
2 Slide the heated tone wheel onto the output shaft. Position it against the spacer.





32. Apply a small bead of sealant to the transfer case cover and extension housing mating surfaces.





33. Install the extension housing.
1 Position the brown clutch coil wire through its hole in the extension housing.
2 Position the extension housing.
3 Install the extension housing bolts.





34. Using the special tool, install the oil seal, if removed.





35. Install the output shaft speed sensor, if equipped.





36. NOTE: Tighten the three motor bolts first, then the bracket bolt.

Install the transfer case shift motor, if equipped.





37. Install the coil wire into the shift motor electrical connector.
1 Install the coil wire and pin.
2 Install the wire connector spacer.





38. Remove the transfer case from the special tool.





39. Install the 4WD indicator switch, if equipped.
40. Install the transfer case in the vehicle.