Part 2
Transfer Case - 1-Speed Torque-On-DemandAssembly
1. Using the special tools, press the front output shaft support bearing into the case.
2. Using the special tool, install the oil seal.
3. Using the special tool, install the oil seal.
4. Install the front output shaft and flange and snap ring.
5. Install the pump assembly and the rear output shaft as an assembly.
6. Install the thrust washer.
7. Install the oil pan magnet.
8. Install the drive chain and the 2 sprockets as an assembly.
9. 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.
10. Install a new snap ring.
11. Install the wave spring.
12. Install the apply cam and 3 steel balls.
13. Install the cam and coil housing assembly.
14. Install the thrust bearing.
15. Using the special tools and a suitable press, install the front output shaft rear bearing into the case.
16. Using the special tools and a suitable press, install the rear output shaft rear bearing into the case.
17. Position and support the clutch coil assembly, then install the 3 nuts.
^ Tighten to 10 Nm (89 lb-inch).
18. CAUTION: Applying excess gasket sealant can damage the internal components.
Apply a 3 mm (0.11 inch) bead of gasket sealant on the rear case mating surface.
19. Assemble the front and rear case halves.
20. Install the transfer case bolts.
^ Tighten the bolts evenly in a star pattern to 25 Nm (18 lb-ft).
21. Install the yoke-to-flange oil seal.
22. Install a new output flange oil seal.
23. NOTE: Align the index marks made during disassembly.
Install the output flange.
24. Install the output shaft yoke washer.
25. Using the special tool to hold the output flange, install the nut.
^ Tighten to 355 Nm (262 lb-ft).
26. Seat the coil wire pin into the electrical connector and install the connector interlock.
27. Install the transfer case in the vehicle.
28. Fill the transfer case.