Assembly

1. Place the transfer case front half in Bench Mounted Holding Fixture and install the front output shaft seal with Front Pump Seal Replacer.





2. Position Seal Protector.





3. Install the input shaft seal with Seal Replacer Input Shaft.





4. Press the front output shaft bearing with Bearing Cone Replacer, Differential Seal Replacer, and Driver Handle.





5. Install the front output shaft.
(1) Install the front output shaft using a soft face hammer.
(2) Install the retaining ring.





6. Install the two chain snubbers with four bolts.





7. Install the input shaft.





8. Press the sun gear shaft bearing with Pinion Bearing Cone Replacer, Bearing Plate, and Bearing Pulling Attachment.





9. Place the viscous clutch with the driven sprocket and the drive chain in the transfer case.





10. Install the sun gear thrust washer.





11. Install the planetary assembly.





12 Install the planetary thrust washer.





13. Attach the ring gear to the rear output shaft.
(1) Position the ring gear on the rear output shaft.
(2) Attach the retaining ring.





14. Install the rear output shaft and ring gear in the rear case half.
(1) Place the rear half of the case in Bench Mounted Holding Fixture.
(2) Install the retaining ring.
(3) Install the rear output shaft and ring gear in retaining ring.





15. Install the speedometer tone wheel and the output shaft bearing.
(1) Install the speedometer gear.
(2) Install the output shaft bearing.





16. Position the rear output shaft bearing and seal.
(1) Put the rear output shaft bearing over the rear output shaft.
(2) Position the rear output shaft seal on the rear output shaft bearing.





17. Install the rear output shaft seal with Front Pump Seal Replacer.