Internal Components

- Tools Required:
- J 37668 Seal Installer
- J 8092 Driver Handle
- J 33832 Bearing Installer/Remover
- J 29169 Bearing Installer/Remover

INSTALL OR CONNECT
1. Rear output shaft seal to the rear bearing retainer using J 37668.





2. Front output bearing to the front case using J 8092 and J 33832.





3. Front output bearing snap ring to the front case.
4. Front output shaft seal to the front case using J 37668.
5. Rear output bearing to the rear case using J 8092 and J 33832.





6. Front input bearing to the front case using J 8092 and J 29169.





7. Front input bearing snap ring to the front case.





8. Selector, detent spring, and detent roller to the front case.
9. Selector shaft through the case and align with spline on the selector.
10. Retainer clip to the selector shaft.





11. Power take off drive gear and the input carrier assembly to the front case.





12. Input carrier snap ring to the input carrier.
13. Input shaft front oil seal to the front case using J 37668.





14. Annulus gear to the front case.





15. Annulus gear snap ring to the front car.





16. Range fork and shift shaft hub aligning the shift hub to the carrier assembly and the shift fork pin to the slot in the selector.
17. Shift rail through the range fork and into the boss in the front case.





18. Mainshaft and oil pump assembly into the carrier assembly. Hub fits in one orientation with the mainshaft.
19. The one piece sprocket and shaft, and drive chain to the front output bearing.





20. The one piece sprocket and shaft, to the mainshaft.





21. Front output shaft ring and washer to the one piece sprocket and shaft.





22. Synchronizer assembly and mode shift fork aligning the synchronizer assembly to the mainshaft drive gear and the mode fork to the shift rail.
23. Synchronizer hub to the synchronizer assembly.





24. Clutch coil housing and clutch coil housing snap ring to the mainshaft.
25. Shift rail spring to the shift rail.
26. Clutch coil to the rear case.
27. Clutch coil nuts to the clutch coil.

Tighten
- Clutch coil nuts to 10 N.m (84 lb. in.).





28. Clutch coil wire through the rear case and clutch coil wire connector to the clutch coil wire.
29. RTV sealer or equivalent to the pump body sealing surfaces and the front and rear case halves.
30. Case bolts to the case halves.

Tighten
- Case bolts to 41 N.m (30 lb. ft.).





31. Rear output bearing snap ring to the mainshaft.

NOTE: The speedometer tone wheel Is important to the proper operation of the anti-lock braking system, speedometer/odometer, cruise control, and the PCM. If It Is removed, It must be replaced with a new part and the old part should be discarded. USE care not to damage the new speedometer tone wheel during Installation.

32. New speedometer tone wheel to the mainshaft using J 5590.