Part 1

ASSEMBLY

BEARINGS AND SEALS










1. Position the input gear bearing in the input retainer bearing bore. Spread the snap-ring captured in the retainer with suitable snap-ring pliers and press the bearing into place. Verify that the snap-ring has engaged the groove in the bearing.
2. Start front output shaft bearing (3) in case. Then seat bearing with Universal Handle C-4171 (1) and Bearing Installer 6953 (2).










3. Install the front output shaft bearing retaining ring.
4. Install the rear output shaft bearing into the rear case half with Bearing Installer 6953 (3) and Universal Handle C-4171 (2).










5. Remove the input gear pilot bearing using Remover Jaws 8240 and Cup 8148.
6. Remove the input gear cup plug with a suitable drift (1)and hammer inserted from the front of the input gear (2).










7. Install a new input gear cup plug with Cup Seal Installer 9045 and Universal Handle C-4171.
8. Install new input gear pilot bearing with Bearing Installer 9047 and Universal Handle C-4171.
9. Remove the front output shaft rear bearing with the screw and jaws from Remover L-4454A (2) and Cup 8148 (3).










10. Install new bearing with Universal Handle C-4171 (1) and Bushing Installer 5066 (3).










11. The bearing (1) bore is chamfered at the top. Install the bearing so it is flush with the lower edge of this chamfer (2).

INPUT AND PLANETARY GEAR










1. Install the annulus gear (2) into the front case half (1).










2. Align and install low range planetary (2) assembly into the front case half (1). Be sure low range planetary pinions are engaged in annulus gear (3).










3. Install the low range planetary plastic spacer (2) onto the low range planetary carrier (1).
4. Clean gasket sealer residue from retainer and inspect retainer for cracks or other damage.
5. Apply a 3 mm (1/8 in.) bead of MOPAR(R) Gasket Maker, or equivalent silicone adhesive, to sealing surface of retainer.










6. Install the front input retainer (1) onto the front case half (2).










7. Install bolts (3) to hold retainer (1) to transfer case (4). Tighten to 21 Nm (16 ft. lbs.) of torque.










8. Install the input gear (2) to the low range planetary assembly and the input gear bearing.
9. Install the input gear retaining snap-ring (3) onto the input gear (2).










10. Install new oil seal in front input retainer with Seal Installer 8841 (2) and Universal Handle C-4171 (1).

SHIFT FORKS AND MAINSHAFT










1. Lubricate mainshaft splines with recommended transmission fluid.
2. Install the drive sprocket drive hub (2) onto the mainshaft (1). Verify that the long shoulder is towards the front of the mainshaft.










3. Install the mode hub (2) onto the mainshaft (1).










4. Install the mode hub snap-ring (3) onto the mainshaft (1).










5. Rotate the mainshaft (1) 180° and install the sliding clutch gear (2) onto the drive sprocket drive hub.










6. Install the mainshaft drive sprocket (2) onto the drive hub.










7. Install the mainshaft drive sprocket retaining ring (3) onto the drive hub.










8. Support front case on wood blocks so case interior is facing up. Place blocks between mounting studs on forward surface of case.
9. Lubricate mainshaft components with transmission fluid.
10. Lubricate sector shaft with transmission fluid and install shift sector (2) in case (1). Position slot in sector so it will be aligned with shift fork pin when shift forks are installed.










11. Assemble and install range fork (1) and hub (2). Be sure hub is properly seated in low range gear and engaged to the input gear.
12. Align and insert range fork pin in shift sector slot.










13. Install mode fork (1) and mode sleeve (2). Verify that the long side of the mode sleeve is towards the front of the transfer case.










14. Install the shift rail (2) through the shift forks and into the shift rail pocket in the front case half (1).