Reassembly
REASSEMBLY1. Before assembly, lubricate all parts with the specified grease oil.
2. If removed, drive the bearing into the front output case bore.
3. Install the internal snap ring that retains the bearing to the front case.
4. If removed, install the front yoke to flange seal in the front case bore.
5. If removed, install the yoke to flange seal into the mounting adapter bore.
6. If the input shaft needle bearing and bushing were removed, install a new bearing and bushing.
7. The recessed face of the sun gear and the snap ring groove on the bearing outer race should be toward the rear of the transfer case.
8. The stepped face of the thrust washer should face toward the bearing.
9. Slide the sun gear, thrust plate and thrust washer into position on the input shaft.
10. Press the bearing over the input shaft.
11. Install the external snap ring to the input shaft.
12. Install the front planet to the sun gear and input shaft.
13. Install the internal snap ring to the planetary carrier.
14. Place the tanged snap ring in the case. Expand the snap ring with the snap ring pliers and install the planetary carrier assembly. Check the installation by holding the case and carefully tapping the face of the input shaft against a wooden block to make sure the snap ring is installed.
15. Remove all traces of gasket sealant from the front case and mounting adapter mating surfaces.
16. Install the high-low shift fork and high-low collar as an assembly into the front planet.
17. Check the pump to make sure the pump rotates freely.
18. Inspect the outside surfaces and bore of the oil pump.
19. Install the output shaft and oil pump in the input shaft. Make sure that the internal splines of the output shaft engage the internal splines of the high-low shift collar. Make sure that the oil pump retainer arm and oil filter leg are in the groove and slot of the front case.
20. Install the oil pan magnet in the slot in the front case just above the oil filter leg.
21. Install the front output shaft in the front case.
22. Install the thrust washer on the rear output shaft.
23. Install the chain, drive sprocket and driven sprocket as an assembly over the output shaft.
CAUTION: The driven sprocket (on the front output shaft) must be installed with the marking REAR facing toward the rear case, if so marked.
24. Install tone wheel onto the front output shaft. Make sure the spline on the tone wheel engages the spline on the front output shaft.
25. Install clutch pack assembly onto the rear output shaft. Make sure that the spline on the clutch pack engages to the spline of the sprocket.
26. Install snap ring onto the rear output shaft. Start the snap ring over the spline and use the wave spring to seat the snap ring in the snap ring groove. If the snap ring will not install, the thrust washer inside the clutch pack may not be seated properly.
27. Three slots on the thrust washer must be aligned with the three tabs on the clutch pack housing.
28. Install the apply cam onto the rear output shaft.
29. Install three balls into the apply cam.
30. Install cam and coil housing assembly onto rear output shaft.
31. Install thrust bearing assembly onto output shaft.
32. Install the clutch coil from inside the rear case until the wire and studs extend through the cover.
33. Install the washers and nuts and tighten to 8 - 11 Nm.
34. Slide the spring spacer on the cam shaft and position it beneath the drive tang.
35. Place the torsion spring on the cam shaft. Position the first spring tang to the left of the cam shaft drive tang.
36. Wind the second spring tang clockwise past the drive tang.
37. Push the torsion spring and sleeve in as far as it will go.
38. Install the helical cam and slide the drive tang between the torsion spring tangs as far as it will go.
39. Install the pin on the tang end of the helical cam into the hole in the front case. Position the torsion spring tangs so that they are pointing toward the top side of the transfer case and just touching the high-low shift fork.
CAUTION: Do not bend the helical cam during installation to the front case because of possible damage to the pin at the tang end of the motor shaft.
40. Install the shift rail through the high-low shift fork and make sure that the reverse gear shift rail is seated in the front case bore.
41. Install upper and lower speed sensors into the cover. Feed the coil wire through the upper speed sensor wire shield.
42. Install upper tone wheel, speedometer gear and rear output seal.
43. Coat the mating surface of the front case with sealant.
44. The following procedure must be followed prior to installing the rear case onto the front case half:
1) Align the output shaft with the rear case output shaft bore.
2) Align the helical cam with the rear case motor bore. If difficulty is encountered with seating the rear case, tap the rear output shaft with a sharp blow using a rubber mallet in a direction away from the triangular shaft while pushing down on the rear case.
45. Install the bolts retaining the case halves and tighten to 25 - 37 Nm (250 - 370 kg-cm, 19 - 25 ft. lbs.).
46. Install shift shaft oil seal if it is not installed.
47. Using pliers equipped with soft jaws, rotate the triangular shaft so it is aligned with the triangular slot in the transfer case shift motor. If triangular shaft will not rotate, rotate the rear output shaft.
48. Slightly loosen the two nuts that attach the slotted support bracket to the end of the motor house.
49. Apply the sealant to motor housing base and install on transfer case.
50. Install the transfer case shift motor.
51. Holding the slotted support bracket tight against the motor housing end secure the bracket to the transfer case, tightening the bolt with lock washer to 8 - 11 Nm (80 - 110 kg-cm, 6 - 8 ft. lbs.).
52. Retighten the two nuts that attach the slotted support bracket to the end of the motor to 3 - 4 Nm (30 - 40 kg-m, 2 - 3 ft. lbs.).