Assembly

ASSEMBLY




1. Remove the input shaft bearing from the front case (3) with Handle C-4171 (1) and Installer 8693A (2).




2. Install the new input gear bearing into the front case (3) using Installer 8152 (2), inverted, and Handle C-4171 (1).




3. Using Installer 7829A (2) and Handle C-4171 (1), remove front output shaft bearing from the front case (3).




4. Start front output shaft bearing in the front case. Using Installer 8152 (2), inverted, and Handle C-4171 (1), seat the bearing in the front case (3).




5. Remove the main shaft rear bearing from the rear case using Installer 5066 and Handle C-4171.
6. Install the new main shaft rear bearing into the rear case (3) using Installer 8152 (2), inverted, and Handle C-4171 (1).




7. Install a new front output shaft seal with Installer 6560.
8. Install the front output shaft assembly (2) into the front case (1) and the front output shaft front bearing.




9. Install the retaining ring (2) onto the front output shaft (1).




10. Install the input gear (2) into the front case (1).
11. Install the new input shaft seal with Installer 9672 and Handle C-4171.




12. Lubricate mainshaft splines with recommended transmission fluid.

NOTE: Replace the mode hub retainer if the legs were distorted during removal.

13. Install the mode hub retainer (2) onto the mode hub (1).




14. Install the mode hub (2) and mode hub retainer onto the differential assembly (1). Make sure the retainer is fully seated onto the differential.




15. Install the differential assembly (1) onto the mainshaft (2).




16. Install the differential snap-ring (1).




17. Install the drive chain guide (1) onto the transfer case.




18. Install the screws (1) to hold the chain guide rail to the front case (2). Tighten the screws to 5-8 Nm (44-71 in.lbs.).




19. Install the input gear thrust washer (1) onto the input gear (2).





NOTE: Be sure that the input spline is engaged with the differential assembly.

20. Install the mainshaft and differential assembly (1) into the front case (2) and input gear.




21. Install the drive sprockets (1, 2) and drive chains (3) as one.




22. Install the front output shaft (1) drive sprocket retaining ring (2).




23. Install the mode hub spacer (2) onto the output shaft (1) and the mode hub (3).
24. Install the mainshaft drive sprocket retaining ring onto the mainshaft.




25. Install the transfer case magnet into the magnet pocket.
26. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3 mm (0.125 inch). Do not use excessive amount of sealer as excess will be displaced into case interior.
27. Install the rear case (1) onto the front case (2).




28. Install the bolts (2) to hold the rear case (1) to the front case (3). Tighten the bolts at the alignment dowel locations first. Tighten the bolts to 27 Nm (20 ft.lbs.).




29. Install a new rear output seal into the rear case with Installer C-3972A.
30. Install the rear output flange (1) onto the output shaft (2).




31. Using Holder C-3281 (1), install the rear companion flange (2) nut. Tighten the nut to 122-176 Nm (90-130 ft.lbs.).




32. Install the transfer case damper (1) onto the rear case (2).




33. Install the bolts (1) to hold the damper (2) to the rear case (3). Tighten the bolts to 27 Nm (20 ft.lbs.).