Assembly

1. Install needle bearings to drive sprocket using tool Nos. J-36370 and J-8092, or equivalent.


2. Ensure sprocket is flush on synchronizer side. Refer to images for aid in assembly of transfer case.

3. Install needle bearings in rear case half using tool Nos. J-36372 and J-8092, or equivalents. Bearings must be flush with boss on case housing.

4. Using tool No. J-37371, or equivalents, install bearing to front case half, then install retainer.






5. Using tool Nos. J-33833 and J-8O92 or equivalents, install bearing to pump retainer housing.

6. Install bearing to input gear using tool Nos. J-36372 and J-8092, or equivalents.

7. Install thrust washer, carrier lock ring and retainer.

8. Install bearing to front case half using tool No. J-36372, or equivalent.

9. Install oil seal to rear extension using tool No. J-33843, or equivalent.

10. Install input bearing retainer seal in input bearing retainer using tool No. J-33831, or equivalent.






11. Install front output shaft seal in front case half using tool No. J-33834, or equivalent.

12. Install magnet in front case half.

13. Attach synchronizer hub to synchronizer sleeve along with three struts, then align reference marks previously made.

14. Attach spring retainer to synchronizer sleeve, then attach main drive synchronizer stop ring to synchronizer sleeve.






15. Install drive sprocket to mainshaft.

16. Place planetary input gear assembly into annulus gear using soft faced hammer.

17. Install bearing retainer (snap ring) to input bearing.






18. Install input bearing retainer bolts (43), and input bearing retainer to front case half. Apply RTV, or equivalent, to bearing retainer mating surfaces. Apply Loctite 242, or equivalent, to bearing retainer bolt threads. Torque bolts to 14 ft. lbs.






19. Install sector and shaft into front case half.

20. Install shift lever 0-ring, plastic washer, shift lever, washer and nut to front case half. Torque nut to 20 ft. lbs.

21. Install range shift hub and range shift fork into front case half. Rotate sector to align range shift fork.






22. Install synchronizer assembly, mode shift fork and rail into front case half.

23. Connect front output shaft to chain, then connect drive sprocket and mainshaft to chain. Mainshaft, drive sprocket, driven sprocket and chain are installed as a unit.

24. Install fork spring onto mode shift rail.

25. Install oil pickup tube, oil tube connector and pump pickup screen into rear case half, then install oil tube 0-ring onto oil tube. Damaging the 0-ring during assembly may result in pump failure.

26. Attach oil pump to oil pick up tube. Apply RTV, or equivalent, to case mating surfaces.






27. Place rear case over mainshaft and onto front case half. Ensure oil pump is not damaged while rear case half is being installed. Install case bolts into case halves after coating bolt threads with Loctite 242, or equivalent. Longer case bolts and their washers are placed in doweled case holes. Torque bolts to 23 ft. lbs.

28. Place input bearing retainer snap ring onto mainshaft.

29. Install retainer snap ring, speedometer gear, speedometer tone wheel and retainer snap ring to mainshaft.

30. Install rear extension housing and extension housing bolts to pump retainer housing. Apply RTV or equivalent, to mating surfaces. Apply Loctite 242, or equivalent, to extension housing bolt threads. Torque bolts to 23 ft. lbs.

31. Install selection plunger, poppet spring, 0-ring seal and poppet screw to front case half. Torque poppet screw to 23 ft. lbs.

32. Install indicator lamp switch and 0-ring to front case housing. Torque switch to 17 ft. lbs.

33. Install front output flange, rubber sealing washer (75), washer (76) and flange nut. Torque nut to 110 ft. lbs.