Steps 1 - 39

ASSEMBLY





1. Using a press, install the input gear bearing into the front case half.





2. Install the input gear bearing retaining ring into the inside of the front case half.





3. Using a press, install the front output shaft bearing into the front case half.





4. Install the front output shaft bearing retaining ring into the front case half.





5. Using J 42737, install the sector bearing into the rear case half.
- Ensure the bearing seal is positioned outward.
- Ensure the lettering on the bearing is positioned inward.





6. Install the sector into the front case half.





7. Secure the sector shaft (2) to the front case half with the sector retaining ring (1).





8. Install the rear retainer bushing into the rear case half.
- Use a hydraulic press to install the rear retainer bushing into the rear case half.
- Install the rear retainer bushing flush with the case half bushing opening.





9. Using J 29162, install the rear output shaft seal into the rear case half.
- Align the seal driver with the notches on the rear output shaft seal.
- Align the rear output seal drain tube with the rear case half drain channel.





10. Using J 33832 and J 8092, install the front output shaft rear bearing into the rear case half.
- Ensure the rounded side of the bearing is install inward toward the rear case half.
- Ensure the lettering side of the bearing is facing outward away from the rear case half.





11. Install the oil fill and drain plugs into the rear case half.
- Tighten the oil fill and drain plugs to 20 Nm (15 ft. lbs.).

- Ensure the oil fill and drain plugs being installed are made of aluminum. A steel plug will cause accelerated corrosion that will destroy the integrity of the magnesium case.
- Do not use an impact tool to install the oil drain and fill plugs.





12. Install the rear output bearing retaining ring into the rear case half.





13. Install the thrust washer into the planetary gear.





14. Install the input gear into the planetary gear.





15. Install the second thrust washer into the planetary gear and over the input gear.





16. Install the thrust plate into the planetary gear and over the input gear.
Ensure the lettering on the surface of the thrust plate is positioned upward during installation.





17. Install the thrust plate retaining ring into the planetary gear and over the input gear.





18. Turn the planetary gear over, and install the pilot bearing into the input shaft.
- Use a press to install the pilot bearing.
- Press the pilot bearing into the input shaft to the point of the ground mark.





19. Install the input shaft into the front case half through the input shaft bearing.
Tap the input shaft lightly until the input shaft is flush against the bearing.





20. Install the cap into the front output shaft.





21. Install the tone wheel onto the front output shaft.





22. Install the driven sprocket and retaining ring onto the front output shaft.





23. install the front output shaft through the front case half and front output shaft
bearing.





24. Install the front output shaft retaining ring onto the front output shaft.





25. Using J 35870, install the front output shaft oil seal over the front output shaft and into the front case half.





26. Install the front input gear case bearing retaining ring onto the front input gear.
- Use snap-ring pliers to position the retaining ring onto the front input gear.
- During installation of the retaining ring, do not scratch/damage the seal surface area of the front input shaft with the retaining ring.





27. Install the front input gear oil seal into the front case half.
- Use J 33831 to install the front input gear oil seal.
- Ensure the side of the oil seal with the part numbers are positioned outward during oil seal installation.





28. Position the range shift sleeve onto the range fork.





29. Install the range fork and range shift sleeve onto the planetary gear.
- Align the gear teeth on the range shift sleeve with the gear teeth on the planetary gear.
- Position the roller on the range fork with the slot in the sector.





30. Install the poppet plunger, poppet spring, poppet bolt o-ring, and poppet bolt into the front case half.
- Tighten the poppet bolt to 20 Nm (15 ft. lbs.).
- Ensure the poppet bolt has a o-ring positioned under the bolt head.
- Apply a light coat of transfer case oil to the mating surface of the poppet bolt O-ring.
- During installation of the poppet plunger, position the sector to align the notch in the sector with the poppet plunger.
- Do not use an impact tool to install the poppet bolt.





31. Ensure the poppet plunger remains in the sector notch during poppet spring and poppet bolt installation.





32. Install the shift rail into the range fork.





33. Install the clutch lever (2) and two clutch lever inserts (1) into the front case half.
- Tighten the two clutch lever inserts to 48 Nm (35 ft. lbs.).
- Ensure the clutch lever is free to move after the clutch lever inserts are tightened.
- Ensure the clutch lever roller (3) is resting on the sector.





34. install the oil restricter into the mainshaft end,
- Perform this procedure only if the main shaft is new.
- Install the oil restricter into the mainshaft to where the top of the oil restricter is flush with the bottom of the funneled chamber.





35. Install one of the clutch outer drum bearings into the mainshaft.
- Use a press to install the bearing.
- Install the bearing with the gear side of the bearing facing down.
- Ensure the bearing is flush with the bottom of the clutch drum.





36. Install the second clutch outer drum bearing into the mainshaft.
- Use a press to install the bearing.
- Install the bearing with the gear side of the bearing facing down.
- Ensure the second bearing is flush with the top of the clutch drum sprocket flange.





37. Install the clutch drum onto the mainshaft.





38. Install the clutch inner drum onto the mainshaft and clutch drum. The clutch inner drum should rest on top of the clutch outer drum.





39. Install the clutch return spring onto the mainshaft and into the clutch inner drum.
- Ensure the prongs on the clutch return spring are positioned upward and away from the inner clutch drum.
- Ensure the flat side of the clutch return spring is down against the clutch inner drum.