Clutch - Assembly

ASSEMBLY










NOTE: Soak new clutch friction plates in transfer case fluid for 20 minutes prior to installation.

1. Install the bottom (outer lugs) clutch plate (1) into the clutch retainer (2). Continue installing clutch plates, a disc with inner teeth followed by a disc with outer lugs, into the clutch retainer (2) until all the clutch plates are installed.





2. Install the wave spring (2) onto the main shaft (1).






CAUTION: When installing the clutch pressure plate, make sure that the wave spring remains piloted on the underside of the plate. Check that the spring does not protrude between the plate and the mainshaft.

3. Install the clutch pressure plate (2) onto the main shaft (1) and clutch assembly.





4. Install the thrust bearing (2) onto the main shaft (1).





5. Install the thrust bearing support plate (2) onto the main shaft (1).






NOTE: The clutch pressure plate must be engaged with the inner drum and held down when installing the retaining ring.

6. Install the thrust bearing support plate retaining ring (2) onto the main shaft (1).





7. Rotate the thrust bearing support plate (1) so that the tab (2) is pointed between the two bolt holes (3) as shown.










8. 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 and potentially clog the oil pump screen.
9. Verify that the tab on the thrust bearing support plate is aligned with the housing alignment dowel furthest from the front output shaft.
10. Install the rear housing (1) into the front housing (2).
11. Install the bolts (2) to hold the rear housing (1) to the front housing (3). Tighten the bolts at the dowel locations first, then the remainder of the bolts in a criss-cross pattern. Tighten the bolts to 27 Nm (20 ft.lbs.).





12. Verify that the shift motor o-ring is clean and properly positioned inside the machined o-ring groove of the shift motor.

NOTE: Verify that the missing tooth (2) in the shift motor drive spline (1).







NOTE: .and the transfer case drive spline (1) missing tooth (2) are aligned. It may be necessary to manually shift the transfer case if the shift motor and transfer case shaft are not aligned.






13. Install the shift motor (1) onto the shift sector (2) and the transfer case (3).





14. Install the bolts (1) to hold the shift motor (2) to the transfer case. Tighten the bolts to 27 Nm (20 ft.lbs.).





15. Install the rear output flange (1) onto the main shaft (2).





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