Assembly

During assembly, lubricate all transfer case components with clean Dexron II type automatic transmission fluid.
1. Replace front output shaft front bearing and seal as follows:
a. Remove shaft oil seal and bearing snap ring from front case.
b. Remove bearing using tools No. J-8092 and J-9276-3 or equivalents.
c. Install new bearing using tools No. J-8092 and J-9276-3 or equivalents.
d. Install bearing snap ring, then the seal using tool No. J-22661 or equivalent.
2. Remove input gear bearing as follows:
a. Remove bearing from front case using tool No. J-29170 or equivalent and a press.
b. Position snap ring on new bearing, then install bearing using a press and a block of wood. Install bearing until snap ring seats against case.
3. Replace input gear pilot bearing as follows:
a. Remove pilot bearing using tool No. J-29369-1 or equivalent and a slide hammer.
b. Install new bearing using tools No. J-8092 and J-33829 or equivalents.
4. Install input gear thrust washers, input gear, retainer and snap ring into low range gear. Ensure snap ring fully seats in groove in gear.
5. Start input gear shaft into bearing in front case, then press gear shaft into front bearing using tool No. J-33829 or equivalent, and a press. Do not press against end surface of low range gear.
6. Install new input gear snap ring into case.
7. Install new front bearing retainer oil seal using tool No. J-33831 or equivalent.
8. Apply a 1/8 inch wide bead of RTV sealer to front bearing retainer sealing surface, then install retainer on front case. Torque retainer attaching bolts to 16 ft. lbs.
9. Install new sector shaft O-ring and bushing into case bore, then position shift sector in case.
10. Install detent pin, spring and plug into case.
11. Install new pads in low range fork.
12. Install low range fork and shift hub assembly. Ensure fork pin is properly engaged in shift sector slot.
13. Assemble differential as follows:
a. Install sprocket gear, planetary gears and new thrust washers in lower case half. Ensure thrust washers are positioned at top and bottom of each gear.
b. Install mainshaft gear, then position upper case half on lower case half.
c. Align reference marks made during disassembly, then install and tighten case attaching bolts.
14. Install inner needle bearing spacer on mainshaft, then the needle bearings and outer spacer. Use petroleum jelly to secure needle bearings on mainshaft during assembly.
15. Slide differential assembly on mainshaft, using care to avoid displacing any needle bearings.
16. Install differential snap ring.
17. Install intermediate clutch shaft, thrust washer and snap ring on mainshaft.
18. Inspect mode fork assembly and replace excessively worn or damaged components as necessary.
19. Assemble mode sleeve to fork, then install sleeve and fork assembly in mainshaft, ensuring sleeve splines are properly engaged in differential splines.
20. Install mainshaft and mode fork assembly into case. Rotate mainshaft as necessary to engage shaft with low range components.
21. Rotate pin on mode fork into shift sector slot, then install shift rail, ensuring rail is properly seated in both shift forks.
22. Align lockpin hole in low range fork with lockpin access hole in case, then drive lockpin into low range fork and shift rail. Install tapered end of lockpin into fork and rail.
23. Install plug in lockpin access hole.
24. Install external shift lever on shift sector shaft. Torque retaining nut to 22 ft. lbs.
25. Install detent plunger, spring and plug into case.
26. Install front output shaft into case.
27. Install drive chain, engaging chain with front output shaft sprocket.
28. Install drive sprocket on mainshaft, then position chain on sprocket and engage sprocket splines with mainshaft.
29. Install drive sprocket snap ring.
30. Replace front output shaft rear bearing as follows:
a. Remove bearing using tool No. J-29369-2 or equivalent and a slide hammer.
b. Install new bearing using tools No. J-33826 and J-8092 or equivalents, then lubricate bearing.
31. Assemble oil pump as follows:
a. Install new oil seal in pump feed housing using tool No. J-33835 or equivalent.
b. Lubricate oil pump gears, then position gears in pump housing.
c. Align pump housing halves, then join halves and torque attaching screws to 14 inch lbs.
d. Install new pickup tube O-ring in oil pump.
32. Slide oil pickup tube into oil pump, then connect screen and connecting hose to tube.
33. Install oil pump, pickup tube and screen assembly into rear case. Ensure screen is properly seated in case slot.
34. Install magnet in front case.
35. Apply a 1/8 inch wide bead of RTV sealer to front case sealing surface, then install front case to rear case, ensuring dowels and mainshaft splines are properly mated. Torque attaching bolts to 30 ft. lbs. A washer must be installed under each bolt at case dowel locations.
36. Replace rear retainer bearing as follows:
a. Tap bearing out of rear retainer using a hammer and brass drift.
b. Install bearing using tools No. J-33833 and J-8092 or equivalents.
37. Apply a 1/8 inch wide bead of RTV sealer to rear retainer sealing surface.
38. Position locating dowel, if previously removed, in rear retainer, then install retainer. Torque attaching bolts to 30 ft. lbs.
39. Install new rear bearing snap ring, ensuring it seats fully in shaft groove.
40. Replace extension housing bushing as follows:
a. Remove rear extension housing seal.
b. Remove extension housing bushing using tools No. J-8092 and J-33839 or equivalents.
c. Install new bushing using tools No. J-8092 and J-33826 or equivalents.
d. Install new seal using tool No. J-33843 or equivalent.
41. Apply a 1/8 inch wide bead of RTV sealer to extension housing sealing surface, then install housing. Torque attaching bolts to 30 ft. lbs.
42. Install front yoke with a new washer and nut. Torque nut to 110 ft. lbs.
43. Install vacuum switch, using a new gasket.
44. Install drain plug and torque to 35 ft. lbs.
45. Add specified quantity of Dexron II type automatic transmission fluid to transfer case, then install fill plug and torque to 35 ft. lbs.