Reassembly

REASSEMBLY
CASE ASSEMBLY
1. If ring gear was removed for replacement, align serrations on OD of new ring gear with those in transfer case. Press in ring gear, chamfered end first. Make sure gear is not cocked and is firmly seated in case.
2. If removed, press two new dowel pins into case.
3. Press in ball bearing to bottom in transfer case and install retaining ring.








4. Position new oil seal and press in to seat seal flange against transfer case.

SHIFT CAM (ELECTRIC PARTS)





1. Insert spacer in torsion spring and install over free end of shift shaft.





2. Slide torsion spring and spacer on shift shaft up to drive tang and position first spring end to left (Viewed from free end of shaft) of drivetang.





3. Twist second spring end to right of drive tang on shift shaft.
4. Push torsion spring and spacer together back as far as they will go.





5. Slide electric shift cam onto shift shaft, drive tang on cam first. Position drive tang on cam so that it will go under drive tang on shift shaft and between spring ends and slide cam as far as it will go.

ADAPTER, INPUT SHAFT AND CARRIER
1. Lay planet carrier assembly on work bench with end having groove for retaining ring up.
2. Install sun gear with hub end up. Rotate gear of planet carrier assembly as required until sun gear is fully meshed.
3. Align tabs and install thrust plate into planet carrier assembly.





4. Install retaining ring (16) to complete gear carrier assembly.
5. If removed, position needle bearing and press into input shaft to dimension shown. Press in new sleeve bearing to complete input shaft assembly.
6. Lift up gear carrier assembly and install input shaft assembly up through gear carrier assembly. Install thrust washer and press bearing over end of input shaft assembly. Retain bearing on input shaft with retaining ring in shaft groove.
7. If removed, press new pin into front adapter.
8. Position oil seal and press into front adapter to dimension shown.
9. Install snap ring in groove in front adapter with long ends of snap ring in adapter groove to complete front adapter assembly.





10. Position front adapter assembly with face that mates with transfer case up. Support on wood blocks to provide clearance for input shaft assembly. Position assembled input shaft and carrier group over front adapter with input shaft down. Lower shaft and carrier group while expanding long ends of snap ring until snap ring engages groove in outside diameter of bearing.
11. Apply continuous 1/16 inch (1.6 mm) bead of sealant (Neutral Cure RTV, Loctite 598) all around transfer case mounting face for front, adapter. Center sealant bead between edges of face. Circle bolt holes.
12. Install assembled adapter, input shaft and carrier group on transfer case and attach with six bolts. Torque bolts to 20 - 34 ft. lbs. (27 - 46 Nm)
13. Install breather bard and torque to 6 - 14 ft. lbs. (8 - 19 Nm).

FRONT OUTPUT SHAFT
1. If removed, press deflector onto yoke.
2. Position output shaft in transfer case and install yoke assembly, oil seal, washer and nut.





3. Hold yoke and torque nut to 150 - 180 ft. lbs. (203 - 244 Nm).

REDUCTION SHIFT
1. If disassembled for parts replacement, assemble reduction shift fork assembly using new pin, roller and retainer assembly. Press pin, roller and retainer assembly in to bore in reduction shift fork until retainer passes completely through and snaps in place. Make sure that cam roller turns freely.
2. Install two fork facings on reduction shift fork assembly.
3. Engage reduction shift fork assembly with reduction hub and position in transfer case, reduction hub in gear carrier assembly previously installed.





4. Install output shaft, engaging output shaft end with input shaft bearings and output shaft spline with reduction hub.

OIL PUMP
1. Locate pump front cover. Front pump cover has tapped holes. Position front cover so that word TOP faces down and turned so that it will be at top of transfer case when installed in vehicle. Install front pump cover over output shaft in this position.
2. Install two pump pins with spring between them in output shaft. Flat surface on both pins must point out and face up. Center pins and spring in output shaft.
3. Push hose coupling onto bard on strainer and install L shaped foot on filter in slot in transfer case. Hose coupling must point in direction of pump assembly.
4. Install pump housing so that word REAR marked on it is up and hose bard points toward hose coupling and strainer. Lower pump housing over upper output shaft, moving pump pins inward and compressing spring so that both pins are contained inside pump housing.
5. Slip hose clamp over free end of hose coupling and push onto hose bard on pump housing. Secure hose clamp over hose coupling on hose bard.





6. Position pump rear cover over assembly with words TOP REAR facing up and located to be at top of transfer case when installed. Position pump retainer on cover so that tab on retainer is in notch in transfer case. Clean threads on four bolts and apply Loctite 222. Align pump holes and install bolts. Torque bolts to 2.9 - 6.3 ft. lbs. (4.0 - 8.5 Nm) while turning output shaft by hand to insure that pump pins move freely.

CHAIN DRIVE
1. On work bench, next to transfer case assembly, position driven sprocket (with internal spline) at front output shaft end of case and drive sprocket (with smooth bore) at output shaft end.
2. Assemble drive chain around sprockets.
3. Grasp each sprocket, hold drive chain tight and parallel with transfer case, and install chain drive assembly over output shaft. It may be necessary to rotate driven sprocket slightly to engage splines on front output shaft.





4. Install spacer on front output shaft. Install snap ring in shaft groove over spacer.

LOCKUP SHIFT
1. Assemble return spring and lockup hub in lockup collar and retain with snap ring, completing 2W-4W lockup assembly.
2. Install rail shaft in transfer case, through reduction shift fork assembly previously installed and into blind hole in case.
3. Engage lockup fork in groove in 2W-4W lockup assembly and slide this group down over output shaft and rail shaft.
4. Install shift collar hub, engaging splines on output shaft and in 2W-4W lockup assembly.





5. On electric shift units only, install electric shift cam group previously assembled and clutch housing as follow:
1) Position electric shift cam group rotated so that end of torsion spring will contact side of reduction shift fork assembly that faces up, toward top of case.
2) Holding rail shaft down, raise up fork assemblies slightly. Rotate electric shift cam group into position so that roller on reduction shift fork assembly is in groove in shift cam and button on lockup fork is on cam end. Then lower this group of parts into the transfer case engaging shift shaft on pin in transfer case.





3) Position clutch housing in transfer case over shift collar hub. Attach with retaining ring in clutch collar hub groove.

CASE COVER





1. Position cover on bed of suitable press so that open face of cover is up and parallel with press bed.
2. Position end of needle bearing with identification marking up and press into cover until upper end of bearing is 1.593 - 1.603 inch (40.47 - 40.97 mm) below face of cover that mates with transfer case.
3. Press in ball bearing to bottom in cover and install snap ring.





4. On electric shift units only, install parts as follow:
1) Verify that four O-rings (one on wire and one each on three studs) are in place on clutch coil assembly. Install clutch coil assembly in inside of cover, with electrical wire and studs extending through cover, with electrical wire and studs extending through cover. Use care not to kink or trap electrical wire under clutch coil assembly. Attach with three nuts and torque to 6 - 8 ft. lbs. (8 - 11 Nm).
2) Install motor bearing and oil seal in cover.
5. Install return spring over rail shaft in transfer case to rest on shift fork.
6. Install magnet in slot in transfer case.





7. Apply continuous 1/16 inch (1.6 mm) bead of sealant (Neutral Cure RTV, Loctite 598) all around transfer case mounting face for cover assembly. Center sealant bead between edges of face. Circle bolt holes. Remove excess if sealant bead is larger than 1/16 inch (1.6 mm).
8. Install cover assembly on transfer case. All of the following alignment conditions must be met for the cover assembly to season transfer case properly.
1) Cover holes with transfer case dowel pins.
2) Cover bearings with output shafts.
3) Blind hole in cover with rail shaft. Make sure spring in not cocked. On electric shift, check with pen light through cover hole for speed sensor.
4) On electric shift units, cover bearing with shift shaft.
9. Install nine bolts positioning identification tag and wiring clip under bolt heads at locations. Torque bolts to 20 - 34 ft. lbs. (27 - 46 Nm).
10. Install speedo gear over spline of output shaft into cover assembly.





11. Press new oil seal into cover assembly.

EXTERNAL ELECTRIC SHIFT
1. Position motor assembly so that triangular slot in motor will align with shift shaft. Move motor in to engage shift shaft and contact cover. Then rotate motor in clockwise direction until motor is in correct position and mounting holes are aligned.
2. Fit O-ring on speed sensor and install speed sensor assembly in cover. Install bracket so that it is over speed sensor and install three bolts. Torque bolts to 6 - 8 ft. lbs. (8 - 11 Nm).








3. Install bolt and washer at bracket end of motor assembly and torque to 6 - 8 ft. lbs. (8 - 11 Nm).