Part 1

ASSEMBLY










1. While holding the retaining ring tabs apart with suitable snap-ring pliers, remove the input shaft bearing (1) from the front case (2).
2. Transfer the retaining ring to the new housing, if necessary, and install the bearing into the front case.










3. Using Installer 6436 and Handle C-4171, remove front output shaft bearing.
4. Start front output shaft bearing in case. Then seat bearing with Handle C-4171 (3) and Installer C-4210 (2).










5. Remove the rear main shaft bearing retaining ring from inside the rear housing.
6. Remove the rear output shaft bearing from the rear case using Installer 5066 (2) and Handle C-4171 (3).
7. Install the rear output shaft bearing into the rear case using Remover/Installer 8281 (2) and Handle C-4171 (3).
8. Install the rear output shaft bearing retaining ring into the rear housing, from inside the rear housing.










9. Install the bottom thrust washer (3 tabs) (1) into the low range planetary (2).










10. Install the top thrust washer (no tabs) (2) onto the input gear (1).










11. Install the input gear (1) and lock plate (2) into the low range planetary (3) and install the lock plate.










12. Install the snap-ring (2) to hold the input gear (1) into the low range planetary (3).










13. Install the input gear and low range planetary assembly (1) into the front housing.










14. Install the retaining ring (2) holding the input gear assembly into the front housing.
15. Install the new input shaft seal with Installer 9672 and Handle C-4171.










16. Install the shift sector (2) into the rear housing (1).










17. Install the retaining ring (2) onto the shift sector shaft (1).










18. Install the oil pick-up tube o-ring (2) into the rear housing (1).










19. Prime the oil pickup tube by pouring a little oil into the tube before installation.
20. Install the oil pick-up tube and screen (1) into the rear housing.










21. Install a new front output shaft seal with Installer 6560.
22. Install the front output shaft (2) into the front housing (1) and the front output shaft front bearing.










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










NOTE: Check that all three shift pads are present and in good condition on the shift fork.

24. Install the range fork and range hub as one into the input gear/low range planetary.










25. Lubricate mainshaft splines with recommended transmission fluid.

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

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










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










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










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










30. Install the intermediate clutch shaft (1).










31. Install the clutch shaft thrust ring (1).










32. Install clutch shaft (2) snap-ring (1).










33. Install the mainshaft and differential assembly (1) into the front housing (2), range sleeve, and input gear/low range planetary.










34. Install the drive chain guides (1) onto the transfer case.










35. Install the screws (2) to hold the chain guide rails (1) to the front housing. Tighten the screws to 5-8 Nm (44-71 in.lbs.).










36. Install the front drive sprocket (1), mainshaft drive sprocket (2), and drive chain (3) as one.










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










38. Install the clutch assembly (2) onto the main shaft (1).










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