Transfer Case Assemble (1 of 29)

Transfer Case Assemble

Tools Required
^ J3289-20 Holding Fixture
^ J8092 Universal Driver Handle
^ J36371 Output Shaft Bearing Installer
^ J36373 Input Sun Gear Ball Bearing Installer
^ J36850 Transjel Lubricant
^ J37668-A Shaft Seal Installer
^ J42738 Seal Installer
^ J45235 Rear Speed Sensor Reluctor Wheel Installer
^ J45236 Front Output Shaft Seal Installer
^ J45238 Input Gear Thrust Bearing Installer
^ J45239 Needle Bearing Installer
^ J45759 Assembly Fixture

Assembly Procedure

Important:
^ Install the input gear seal after the transfer case is assembled.
^ Do not cock the bearing when installing. Ensure the bearing is being installed square to the bore.





1. Using a suitable bearing installer, install the rear output shaft bearing. Ensure the bearing installer is used against the outer race of the bearing.





2. Using the J36371, install the front output shaft rear bearing into the rear case half.





3. Using the J8092 (1) and the J45239 (2), install the control actuator lever shaft bearing until it bottoms in the bore. The seal side of the bearing faces the encoder motor.





4. Install the control actuator lever shaft in the rear case half.





5. Install a new control actuator lever shaft retaining ring.





6. Install the oil pump screen and oil pump hose to the oil pump suction pipe.





7. Install a new O-ring seal on to the oil pump suction pipe.
8. Lightly lubricate the O-ring seal with transfer case oil.
9. Install the oil pump suction pipe assembly in the rear case half. Ensure the oil pump suction pipe is fully seated.





10. Install the chip collector magnet in the rear case half.





11. Apply a thin layer of bonding adhesive LOCTITE 680 or equivalent to the vent, if removed.
12. Tap the vent into the case. Ensure the vent is aligned in the direction shown.

Important: Install the front output shaft after the transfer case is assembled.





13. Using the J36371, install the front output shaft front bearing into the front case.





14. Using a press, install the input gear bearing into the front case.
^ Ensure the press plates fit properly on the case.
^ Use a suitable press tool that fits to the bearing outer race.

Important: Apply J36850 to the thrust washer in order to hold the thrust washer on the planetary gear assembly.

15. Apply a layer of the J36850 on the large diameter thrust washer.
16. Install the large diameter thrust washer on the planetary gear assembly.





17. Install the planetary gear assembly into the front case. Rotate the planetary gears to align with the annulus gear.
18. Ensure the large diameter thrust washer is aligned to the input gear bearing race.





19. If removed, lightly lubricate the input gear bore seal with transfer case fluid.

Important: The bore seal installation depth should not block the oil gallery hole in the input gear. If installed too far, the transmission output shaft may contact the bore seal.

20. Install a new input gear bore seal into the input gear. Push the bore seal into place by hand until the seal is just past the oil gallery hole in the input gear. Ensure the bore seal is square in the bore.





21. If removed, install the input gear thrust bearing into the input gear using the J8092 (1) and the J45238 (2).

Important: Apply J36850 to the thrust washer in order to hold the thrust washer on the input gear.





22. Apply a layer of J36850 on to the small diameter thrust washer.
23. Install the small diameter thrust washer on to the input gear.





24. Position the input gear in the planetary gear assembly.
^ Ensure the thrust washers are in the correct position.
^ Ensure the input gear and the planetary gears are correctly meshed.





25. Using a press, press the input gear assembly into the input gear bearing.
25.1. Support the front case half on press plates to allow the input gear to protrude.
25.2. Support the inner race of the input gear bearing.
25.3. Use a suitable press plate on the end of the input gear.
25.4. Press on the input gear until fully seated against the input gear bearing.
26. Inspect for proper assembly by turning the input gear. The input gear and planetary gears should turn without roughness or binding. If binding or roughness is present, inspect for debris in the planetary gears or for improper assembly.





27. Install the rear output shaft thrust washer. Align the tabs with the shaft splines.





28. Install a new retaining ring for the clutch housing on the rear output shaft. Ensure the retaining ring is properly installed in the groove.





29. Install the drive sprocket on to the clutch housing.