Steps 1 - 34

Transfer Case Assemble





^ Tools Required
- J 8092 Universal Handle
- J 36370 Drive Sprocket Needle Bearing Installer
- J 36373 Input Sun Gear Ball Bearing Installer
- J 36850 Transjel Lubricant
- J 37668-A Seal Installer
- J 42737 Sector Bearing Installer
- J 42738 Seal Installer
- J 44295 Clutch Pack Shimming Kit
- J 44636-1 Front Output Shaft Seal Protector
- J 44636-2 Front Output Shaft Seal Installer
- J 45237 Input Shaft Bore Seal Installer
- J 45380 Transfer Case Rear Bushing Remover and Installer

Important: Use only new retaining rings.

1. Install the input bearing.





2. Install the input bearing retaining ring.





3. Install the front output shaft front bearing.
4. Install the front output shaft front bearing retaining ring.





5. Using the J 8092 (1) and the J 36370 (2), install the front output shaft rear bearing.





6. Using the J 42737, install the control actuator lever shaft bearing.





7. Lubricate the control actuator lever shaft bearing.
8. Install the control actuator lever shaft.





9. Install the NEW retaining ring for the control actuator lever shaft. Ensure the retaining ring is fully seated.





10. If removed, install the front output shaft rear bearing race, using a hydraulic press and a suitable driver.






11. Install the front output shaft assembly.





12. Install the front output shaft retaining ring.





13. Lubricate the thrust washer for the input shaft with J 36850 or equivalent.
14. Install the input shaft thrust washer. Align the tabs on the thrust washer with the slots in the planetary carrier.





15. Install the pilot bearing in the input shaft, using the J 8092 (1) and the J 45237 (2).
The bearing installed depth is 33 mm (1.3 inch) from the face of the gear or just below the tapered bore.





16. Install the input shaft assembly.





17. Lubricate the input shaft thrust bearing with J 36850 or equivalent.
18. Install the input shaft thrust bearing.





Important: When installing the input gear thrust bearing washer in the planetary carrier, ensure that the lettering is facing up.

19. Lubricate the input gear thrust bearing washer with J 36850 or equivalent.
20. Install the input gear thrust bearing washer.





21. Install the retaining ring for the planetary gear shaft.





22. Install the planetary gear carrier.





23. Install the outer retaining ring for the input gear bearing.





24. Install new shift fork pads, if removed.
25. Install the range shift sleeve in the range fork.





26. Align the range shift sleeve on the planetary carrier.
27. Align the roller on the range fork in the control actuator lever slot.
28. Install the range shift fork.





Important: Install the shift fork shaft in the range fork assembly, with the machined hole facing the bottom of the front case half.

29. Install the shift fork shaft.





30. Install the clutch lever.





Notice: Refer to Fastener Notice in Service Precautions.

Important: When performing the following service procedure, ensure that the clutch lever pivot pins are tightened evenly. Ensure that the clutch lever moves freely after the pivot pins are tightened and engaging the lever.

31. Install the clutch lever pivot pins in the front case half.
^ Tighten the clutch lever pivot pins to 40 Nm (30 ft. lbs.).





Important: Ensure that the shift detent plunger is seated correctly on the control actuator lever.

32. Install the shift detent plunger.
33. Install the shift detent spring.
34. Lightly lubricate a NEW shift detent plunger O-ring seal with transfer case fluid.