Install
Install (Figures 2 and 3)
Tools Required:
J 8092 Drive Handle
J 33790 Bearing Installer and Remover
J 33833 Bearing Installer and Remover
1. Front output bearing (61) to the new front case half P/N 15635347 (45) using J 8092 and J 33833.
2. New front output shaft seal P/N 15579788 (72) to the new front case half (45).
3. Front output bearing retainer ring (snap ring)
(60) to the new case half.
4. New input seal P/N 14095609 (42) into retainer
(44) if it was removed in step 24 above.
5. Input bearing (40) and input bearing retainer
(39) to the new case half using J 36372.
6. Planetary carrier (36) and the input gear (38) to the annulus gear (62) using a soft hammer.
7. Retainer snap ring to the input gear (38). Input bearing retainer (44) and input bearing retainer bolts (43) to the front case half (45).
- Clean mating surfaces and apply RTV or equivalent on bearing retainer mating surfaces.
NOTE: Do not block oil feed hole from case to bearing retainer
- Apply Loctite 242 (R) or equivalent on bearing retainer bolts.
- Tighten bolts to 19 N-m (14 lbs.ft.).
8. New O-ring seal P/N 14095598 (67) and new plastic washer (retainer) P/N 14037958 (66) into the front case half.
9. New sector with shaft P/N 15637215 (55) into the front case half.
10. Range shift fork (51) and range shift hub (34) into the planetary carrier (36).
- It is necessary to rotate the sector with shaft (55) to obtain clearance when installing the range fork (51).
Inspect
The teeth of the synchronizer stop ring (28) and drive sprocket (20) for damage. If the parts are to be replaced due to damage or in cases of customer complaint of clash when shifting from 2HI to 4HI, follow steps 11, 12, and 13. Otherwise, skip to step 14.
11. New drive sprocket P/N 15579803 (20) to the main shaft (19).
12. New synchronizer stop ring P/N 14071703 (28) to the drive sprocket (20).
13. Synchronizer assembly (81) to the main shaft.
14. Mainshaft (19)/drive sprocket (20), chain (58), and front output shaft (21) as a unit. Mode shift fork (54) and shift rail (48) will be installed with the mainshaft.
15. Fork shift spring (52).
Mainshaft Extension and Oil Pump
16. Rear case (17) over mainshaft (19) and onto the front case half (45).
- Clean case mating surfaces and apply RTV sealer or equivalent to the mating surfaces.
- Transfer dowels from old case half to new case half if necessary.
Important
Be careful not to damage the oil pump (12) while installing the rear case half (17) (figure 1).
17. Case bolts (3) into case halves.
- Apply Loctite 242 (R) or equivalent on pump housing bolt threads.
- The two longer bolts and washers into the doweled case holes (33).
- Tighten bolts to 31 N-m (23 lbs.ft.).
18. Speedometer tone wheel (11) to the main shaft (19).
19. Pump retainer housing (8) and pump housing bolts (7) to the rear case half (17).
- Clean mating surfaces and apply RTV sealer or equivalent to the mating surfaces.
- Apply Loctite (R) or equivalent on pump housing threads.
- Pump housing bolts are shouldered (7).
- Tighten bolts to 41 N-m (30 lbs.ft.)
20. Output bearing retainer (snap ring) (5) to the main shaft (19).
21. Rear extension housing (4) and extension housing bolts (3) to the pump retainer housing (8).
- Clean mating surfaces and apply RTV sealer or equivalent to the mating surfaces.
- Apply Loctite 242 (R) or equivalent on the extension housing bolts.
- Tighten bolts to 31 N-m (23 lbs.ft.).
External Components
22. Poppet plunger (70), poppet spring (71), new O-ring seal P/N 14071849 (69), and poppet screw (68) to the front case half (45).
- Tighten poppet screw to 31 N-m (23 lbs. ft.).
- New poppet plunger P/N 15633556 (70) group A vehicles only.
- New poppet spring P/N 15633557 (71) group A vehicles only.
- New poppet screw P/N 15633558 (68) group A vehicles only.
23. Vacuum switch (46) and new O-ring P/N 14071849 (47) to the front case housing.
- Tighten switch to 24 N-m (17 lbs.ft.).
24. Front output flange (74), rubber sealing washer (75), washer (76), and flange nut (77).
- Tighten nut (26) to 149 N-m (110 lbs.ft).
25. New vent pipe P/N 15581915 in new front case half (group A vehicles only).
- Lightly coat end of vent pipe with Loctite 609 (R) or equivalent.
26. Transfer case into vehicle.
- Refer to section 7D of the appropriate S/T Service Manual for complete transfer case replacement procedure.