Assembly

During assembly, lubricate all internal components with Dexron 2 or petroleum jelly if specified. Do not use any other types of lubricant.
1. Install new input gear and rear output shaft bearing seals and apply petroleum jelly to seals. Seals must seat flush with edge of seal bore or in seal groove in case.
2. Install input gear thrust bearing race in case counterbore and thrust bearing on input gear, then install gear and bearing in case.
3. Install mainshaft thrust bearing in bearing recess in input gear.
4. Install planetary assembly on input gear. Ensure planetary pinion teeth are fully meshed with input gear.
5. Install new sector shaft O-ring on mode sector shaft.
6. Install mode sector through range sector.

Fig. 26 Range sector installation:

7. Install range sector in front case.
8. Install operating lever and snap ring on range sector shaft, then the lever attaching washer and locknut on mode sector shaft. Torque locknut to 17 ft. lbs.

Fig. 27 Annulus gear assembly installation:

9. Assemble annulus gear, range fork and rail, then install assembly on and over planetary assembly. Ensure annulus gear is fully meshed with planetary pinions.
10. Install annulus thrust washer and annulus retaining ring on annulus gear hub.
11. Install detent spring, plunger, ball and screw in front case detent bore. Torque screw to 22 ft. lbs.

Fig. 28 Mode & locking clutch sleeve identification:

12. Assemble and install locking fork, fork brackets, fork springs and clutch sleeve. Ensure lug on fork is fully seared in range sector detent. Splines in locking clutch sleeve and mode clutch sleeve are different. Ensure correct sleeve is installed in corresponding shift fork.
13. Install range fork lug in range sector detent notch, then place range sector in high range position.

Fig. 29 Mode fork, shift rail & mode clutch sleeve installation:

14. Assemble and install mode fork, shift rail and mode clutch sleeve.

Fig. 30 Mainshaft needle bearing installation:

15. Install thrust washer, new O-ring, needle bearings and bearing spacers on mainshaft.
16. Coat shaft bearing surface and all 82 needle bearings with petroleum jelly.
17. Install 41 needle bearings and long bearing spacer, then install remaining 41 bearings and short spacer.
18. Install spline gear on mainshaft, using care not to displace bearings.

Fig. 31 Sprocket carrier & drive sprocket assembly:

19. Install sprocket carrier in drive sprocket using reference marks made during disassembly. Assemble sprocket carrier and drive sprocket so tapered teeth on carrier are on same side as recess in drive sprocket.
20. Install sprocket carrier bearings and spacers.
21. Coat carrier bore and all 120 needle bearings with petroleum jelly.
22. Install center spacer and position 60 bearings in each end of carrier, then install two remaining spacers, one on each side of carrier.

Fig. 32 Mainshaft assembly:

23. Install sprocket carrier and drive shaft on mainshaft. Ensure recessed side of drive sprocket faces downward.
24. Install clutch gear thrust washer on mainshaft.

Fig. 25 Side & clutch gear replacement:

25. Install clutch gear on side gear. Ensure tapered edge of clutch gear faces side gear teeth.
26. Install side and clutch gear assembly on mainshaft. Ensure side gear is fully seated in sprocket carrier.

Fig. 23 Mainshaft assembly replacement:

27. Install mainshaft and gear assembly in case. Ensure mainshaft is fully seated in input gear.
28. Install driven sprocket and snap ring on front output shaft using reference marks made during disassembly.
29. Install front output shaft front thrust bearing, then the thick race, bearing and thick race in case.
30. Install drive chain on driven sprocket, then lift and tilt driven sprocket and chain and install opposite end of chain on drive sprocket. Align front output shaft with shaft bore in front case and install shaft in case. Ensure shaft thrust bearing is seated in case.

Fig. 21 Front output shaft thrust bearing replacement:

31. Install front output shaft rear thrust bearing assembly on front output shaft. Install thin race first, then the bearing and thick race.

Fig. 20 Differential shims & speedometer drive gear replacement:

32. Install viscous coupling on side gear and clutch gear. Ensure coupling is fully seated on clutch gear, clutch gear is flush with coupling and gear teeth are visible.
33. Apply petroleum jelly to mainshaft pilot bearing surface and all 15 pilot roller bearings, then install bearings on shaft.
34. Install rear output shaft on mainshaft and into viscous coupling. Shaft must be completely seated in coupling. If not, tap into position with a rubber mallet. Use caution not to displace pilot bearings during shaft installation.
35. Install oil pump on rear output shaft, then a new rear output shaft bearing oil seal in rear case.
36. Apply bead of Loctite 515 sealer or equivalent to rear case mating surface and install magnet in case, if removed.
37. Install rear case on front case. Ensure alignment dowels on ends of front case are lined up with bolt holes in rear case. If rear case will not fully seat in front case, check for following oil in range fork rail bore; front output shaft rear thrust bearing assembly not properly aligned with rear case; mainshaft not fully seated; rear case and oil pump misaligned.
38. Install case attaching bolts and torque to 23 ft. lbs. Ensure flat washers are used on bolts at case ends with alignment dowels.
39. Install speedometer drive gear and differential shims on rear output shaft.
40. Install rear retainer on rear case. Tighten bolts securely but not to final torque.
41. Install front and rear output shaft yokes and original yoke nuts. Tighten nuts finger tight only.
42. Install a dial indicator onto rear retainer, so plunger contacts rear yoke nut.
43. Rotate front output shaft 10--12 revolutions and zero dial indicator, then rotate shaft one more revolution and note dial indicator reading.
44. Correct endplay is 0.002-0.010 inch. If not within specifications, remove retainer and add or remove shims as necessary to bring endplay within limits.
45. Remove front and rear yokes and rear retainer. Discard original yoke nuts.
46. Apply Loctite 515 sealer or equivalent to retainer mating surface and retainer bolts, then install retainer and torque bolts to 23 ft. lbs.
47. Install yokes with new seal washers and nuts. Torque nuts to 120 ft. lbs. Hold yokes with tool No. J-8614-01 or equivalent while tightening nuts.
48. Apply sealer to detent bolt, then install ball, spring and bolt. Torque bolt to 23 ft. lbs.
49. Install drain plug and washer and torque plug to 18 ft. lbs.
50. Fill transfer case with six pints of Dexron 2 transmission fluid and install fill plug with washer. Torque fill plug to 18 ft. lbs.