Assembly

Assembly





1. CAUTION: Do not crush the seal.

Using the special tools, install the shifter shaft seal.





2. Using the special tools, press the front output shaft support bearing into the case.





3. Using the special tool, install the oil seal.





4. Using the special tool, install the oil seal.





5. Install the front output shaft and flange and snap ring.





6. Install the ring gear, if removed.
1 Position the ring gear.
2 Install the snap ring.





7. Install the dampener snubber.





8. CAUTION: Do not crush the bearing cage.

If removed, using a suitable press and the special tool, install the bushing and the bearing.





9. If removed, using a suitable press, install the planetary gear carrier support bearing.





10. Install the snap ring.





11. Install the front planetary gear set assembly.
1 Expand the snap ring.
2 Position the front planetary gear set assembly, and release the snap ring.





12. Install the shift rail.





13. Install the reduction shift fork and the high-low collar as an assembly.





14. Install the electric shift cam assembly.





15. Install the pump assembly and the rear output shaft as an assembly.





16. Install the thrust washer.





17. Install the oil pan magnet into its slot in the case.





18. Install the drive chain and sprockets as an assembly.





19. Install the tone wheel.





20. CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as it was located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem can occur.

Install the clutch pack assembly.





21. CAUTION: Use a new snap ring.

Install a new snap ring.





22. Install the wave spring.





23. Install the apply cam and balls.
1 Install the apply cam.
2 Install the steel balls.





24. Install the cam and coil housing.





25. Install the thrust bearing.





26. Using the special tools, press the front output shaft rear bearing, and the rear output shaft support bearing into the case.





27. Position and support the clutch coil assembly, and install the nuts.

28. CAUTION: Applying too much silicone sealant can plug the fluid filter and cause transfer case failure.

NOTE: Make sure the transfer case mating surfaces are clean.

Apply a 3 mm (1/8 inch) bead of sealant to the transfer case mating surfaces.
29. Position the transfer case halves together.





30. Install the bolts, tighten them evenly in a star pattern.
31. Install the tone wheel.





32. Install the oil seal.





33. NOTE: Align the index-marks made during disassembly.

Assemble the following components:
1 Install the output flange.
2 Install the oil seal.
3 Install the output flange washer.
4 Install the nut.





34. While holding the flange with the special tool, tighten the nut.





35. CAUTION: Make sure the sensor seats flat against the boss.

Install the front output shaft speed sensor.





36. CAUTION: Make sure the sensor seats flat against the boss.

Install the rear output shaft speed sensor.





37. NOTE: Make sure the motor mounting surfaces are clean.

Apply a 3 mm (1/8 inch) bead of sealant to the motor mounting surface on the case.





38. Install the transfer case shift motor.





39. Install the coil wire pin in the electrical connector.
1 Install the coil wire pin.
2 Install the connector interlock.
40. Install the heat shield.
41. Install the dampener.
42. Remove the transfer case from the special tool.
43. Install the transfer case in the vehicle.