Assembly

Fig. 52 Installing Sun Gear Components. Borg-Warner 4472 Transfer Case:

Fig. 53 Installing Gear Ring Snap Ring. Borg-Warner 4472 Transfer Case:

Fig. 54 Installing Output Shaft Bearing Snap Ring. Borg-Warner 4472 Transfer Case:

Fig. 55 Installing Output Shaft Rear Bearing. Borg-Warner 4472 Transfer Case:

Fig. 56 Installing Output Shaft Bearing Snap Ring. Borg-Warner 4472 Transfer Case:

1. Install viscous clutch, drive sprocket, drive sprocket spacer and sun gear shaft bearing onto sun gear shaft, Fig. 52.
2. Using tool J-7079 and tool J-38212 or equivalent, install input shaft pilot bearing into output shaft assembly.
3. Install output shaft assembly to gear ring.
4. Install gear ring snap ring to gear ring, Fig. 53.
5. Install output shaft bearing and bearing snap ring to front cover, Fig. 54.
6. Using tool J-7079-2 and tool J-38212 or equivalent, install output shaft rear bearing to rear case half, Fig. 55.
7. Install output shaft bearing snap ring, Fig. 56.
8. Apply Loctite 51580 or equivalent to rear case half extension housing sealing surface.
9. Position extension housing to rear case, then install extension housing retaining bolts. Torque retaining bolts to 35 ft. lbs.
10. Install speed sensor and speed sensor retaining bolt. Torque retaining bolt to 10 inch lbs.

Fig. 57 Installing Output Shaft Oil Seal. Borg-Warner 4472 Transfer Case:

Fig. 58 Aligning Oil Seal. Borg-Warner 4472 Transfer Case:

Fig. 59 Installing Sun Gear Shaft Assembly. Borg-Warner 4472 Transfer Case:

11. Using tool J-37668 or equivalent, install output shaft oil seal to extension housing. Align water drain hole in oil seal with drain groove in extension housing, Figs. 57 and 58.
12. Install planetary carrier assembly thrust washer to output shaft assembly and align with input shaft pilot bearing.
13. Install planetary carrier assembly into gear ring.
14. Install sun gear shaft assembly into planetary carrier assembly, aligning viscous clutch teeth to gear ring spline, Fig. 59.
15. Install input shaft into input shaft pilot bearing, aligning input shaft with sun gear shaft thrust washer and planetary carrier assembly thrust washer.
16. Install driven sprocket onto front output shaft.
17. Install drive chain onto driven sprocket.

Fig. 60 Installing Drive Chain Assembly. Borg-Warner 4472 Transfer Case:

Fig. 61 Installing Output Flange Assembly. Borg-Warner 4472 Transfer Case:

Fig. 62 Installing Output Flange Retaining Nut. Borg-Warner 4472 Transfer Case:

18. Install drive chain over drive sprocket and front output shaft into output shaft rear bearing, Fig. 60.
19. Install front output shaft spacer on front output shaft.
20. Install magnet to rear case half, then apply Loctite 51580, or equivalent to rear case half front cover sealing surface.
21. Install front cover and front cover retaining bolts to rear case half. Torque retaining bolts to 35 ft. lbs.
22. Using tool J-37668 or equivalent, install front output shaft oil seal to front cover.
23. Using tool J-38216 or equivalent, install input shaft oil seal.
24. Install front output flange to front output shaft, Fig. 61.
25. Install rubber sealing washer, steel flat washer and new front output flange nut, Fig. 62. Torque flange nut to 80 ft. lbs.