Assembly
Transfer Case - 2-Speed Torque-On-DemandAssembly
1. CAUTION: Do not crush the seal.
Using the special tool, install the shifter shaft seal.
2. Using the special tools, press the front output shaft support bearing into the case.
3. Using the special tool, install the oil seal.
4. Using the special tool, install the oil seal.
5. Install the front output shaft and flange and snap ring.
6. CAUTION: Do not crush the bearing cage.
Using a suitable press and the special tool, install the bushing and the bearing, if removed.
7. Using a suitable press, install the planetary gear carrier support bearing, if removed.
8. Install the snap ring.
9. Install the front planetary gear set assembly.
1 Expand the snap ring.
2 Position the front planetary gear set assembly and release the snap ring.
10. Install the shift rail.
11. Install the reduction shift fork and the high-low collar as an assembly.
12. CAUTION: Do not disassemble the electric shift cam assembly.
Install the electric shift cam assembly.
13. CAUTION: Do not disassemble the pump assembly.
Install the pump assembly and the rear output shaft as an assembly.
14. Install the thrust washer.
15. Install the oil pan magnet.
16. Install the drive chain and the 2 sprockets as an assembly.
17. CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as it was located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem can occur.
Install the clutch pack assembly.
18. CAUTION: Use a new snap ring.
Install the snap ring.
19. Install the wave spring.
20. Install the apply cam and 3 steel balls.
21. Install the cam and coil housing assembly.
22. Install the thrust bearing.
23. Using the special tools and a suitable press, install the front output shaft rear bearing into the case.
24. Install the driven sprocket thrust washer.
25. Using the special tools and a suitable press, install the rear output shaft rear bearing into the case.
26. Position and support the clutch coil assembly, then install the 3 nuts.
^ Tighten to 10 Nm (89 inch lbs.)
27. CAUTION: Applying excess silicone rubber can damage the internal components.
Apply a 3 mm (0.11 inch) bead of silicone rubber on the rear case mating surface.
28. Assemble the front and rear case halves.
29. Install the transfer case bolts.
^ Tighten to 25 Nm (18 ft. lbs.) evenly in a star pattern.
30. Install the yoke-to-flange oil seal.
31. Install a new output flange oil seal.
32. NOTE: Align the index marks made during disassembly.
Install the output flange.
33. Install the output shaft yoke washer.
34. Using the special tool to hold the output flange and install the nut.
^ Tighten to 355 Nm (262 ft. lbs.)
35. NOTE: Make sure the motor mounting surfaces are clean.
Apply a 3 mm (0.11 inch) bead of sealant to the motor mounting surface on the case.
36. Position the transfer case shift motor and install the 4 bolts.
^ Tighten to 10 Nm (89 inch lbs.)
37. Install the coil wire pin to the electrical connector.
^ Install the coil wire pin (pin 16).
^ Install the connector interlock.
38. Position the heat shield and install the 3 heat shield bolts.
^ Tighten to 16 Nm (12 ft. lbs.)
39. Install the transfer case in the vehicle.
40. Fill the transfer case.