Part 2

ASSEMBLY


FRONT OUTPUT SHAFT AND DRIVE CHAIN










1. Install the front output shaft (2) into the front output shaft bearing.










2. Insert front sprocket in drive chain.
3. Install drive chain (2) around mainshaft sprocket (1). Then position front sprocket over front shaft.
4. Raise mainshaft about 2.54 cm (one inch) and seat front sprocket on front output shaft.










5. If mainshaft and mode sleeve were unseated during chain installation, align and reseat mainshaft in input gear and hub.
6. Install front sprocket (1) retaining ring (2).










7. Install spring (2) and cup (1) on shift rail.










8. Insert magnet (1) in front case pocket (2).

OIL PUMP AND REAR CASE










CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft inner bearing race and will become mis-aligned if the bolts are loosened. If the transfer case failure has generated any debris which may have become trapped in the oil pump. the rear case and oil pump assembly MUST be replaced.

1. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into case interior.
2. Align oil pump with mainshaft and align shift rail with bore in rear case. Then install rear case (1) and oil pump assembly.










3. Install 4-5 rear case(1)-to front case (2) bolts to hold rear case in position. Tighten bolts snug but not to specified torque at this time.

CAUTION: Verify that shift rail, and case alignment dowels are seated before installing any bolts. Case could be cracked if shaft rail or dowels are misaligned.











4. Apply Loctite(TM) 242 to remainder of rear case-to-front case bolt threads and install bolts. Tighten bolts to 20-27 Nm (15-24 ft. lbs.),
5. Install rear output bearing (2) snap-ring (3) to output shaft.

REAR EXTENSION










1. Install new seal in rear extension housing seal with Installer D-163 and Universal Handle C-4171.
2. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of rear extension housing. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess could be displaced into output bearing.
3. Align and install rear extension housing (1) on retainer.
4. Apply Mopar(R) Silicone Sealer to threads of rear extension housing bolts. Then install and tighten bolts to 16-24 Nm (12-18 ft. lbs.) torque.

COMPANION FLANGE AND RANGE LEVER










1. Install range lever (1) and bolt (2) on sector shaft. Tighten bolt to 27-34 Nm (20-25 ft. lbs.) torque.










2. Inspect the o-ring on the transfer case position sensor. Replace the o-ring if necessary.
3. Install the transfer case position sensor (1) in the front case (2). Tighten sensor to 20-34 Nm (15-25 ft. lbs.) torque.










4. Install new seal washer (1) on front output shaft.
5. Lubricate companion flange hub with transmission fluid and install flange onto the front output shaft.
6. Install new flange nut onto front output shaft.
7. Tighten flange nut to 122-176 Nm (90-130 ft. lbs.) torque.