Steps 1 - 48
Transfer Case AssembleAssembly Procedure
^ Tools Required
- J 8092 Universal Handle
- J 36370 Drive Sprocket Needle Bearing Installer
- J 36373 Input Sun Gear Ball Bearing Installer
- J 36850 Transjel Lubricant
- J 37668-A Seal Installer
- J 42737 Sector Bearing Installer
- J 42738 Seal Installer
- J 43484 Seal Installer
- J 44295 Clutch Pack Shimming Kit
- J 45237 Input Shaft Bore Seal Installer
- J 45380 Transfer Case Rear Bushing Remover and Installer
Important: Use only new retaining rings.
1. Install the input bearing.
2. Install the input bearing retaining ring.
3. Install the front output shaft front bearing.
4. Install the front output shaft front bearing retaining ring.
5. Using the J 8092 (1) and the J 36370 (2), install the front output shaft rear bearing.
6. Using the J45239 (2) and J8092 (1) install the control actuator lever shaft bearing. The seal on the bearing faces outward.
7. Using transfer case fluid, lubricate the control actuator lever shaft bearing.
8. Install the control actuator lever shaft.
9. Install the NEW retaining ring for the control actuator lever shaft. Ensure the retaining ring is fully seated.
10. If it is a new shaft, or if the cup plug was removed, install the cup plug in the front output shaft, using a suitable driver.
11. If removed, install the front output shaft rear bearing race, using a hydraulic press and a suitable driver.
12. Using the J 36373 and a hydraulic press, install the tone wheel on the front output shaft.
13. Install the front output shaft assembly.
14. Install the front output shaft retaining ring.
15. Using the J45239 (2) and J8092 (1) install the control actuator lever shaft bearing. The seal on the bearing faces outward.
16. Using transfer case fluid, lubricate the control actuator lever shaft bearing.
17. Install the control actuator lever shaft.
18. Install the NEW retaining ring for the control actuator lever shaft. Ensure the retaining ring is fully seated.
19. Lubricate the thrust washer for the input shaft with J 36850 or equivalent.
Important: The transfer case may use either a 4 pinion or 6 pinion planetary carrier assembly with the 27 tooth input gear version of the transfer case, transmission RPO M30. If the 6 pinion planetary carrier assembly used with the 27 tooth input gear requires replacement, the service part will be a 4 pinion planetary carrier assembly. The 4 pinion and 6 pinion planetary carriers are interchangeable. The 32 tooth input gear transfer case version used with transmission RPO MT1 and RPO MN8 will still use the 6 pinion planetary carrier assembly.
20. Install the input shaft thrust washer. Align the tabs on the thrust washer with the slots in the planetary carrier.
21. Install the pilot bearing in the input shaft, using the J 8092 (1) and the J 45237 (2).
The bearing installed depth is 33 mm (1.30 inch) from the face of the gear or just below the tapered bore.
22. Install the input shaft assembly.
23. Lubricate the input shaft thrust bearing with J 36850 or equivalent.
24. Install the input shaft thrust bearing.
Important: When installing the input gear thrust bearing washer in the planetary carrier, ensure that the lettering is facing up.
25. Lubricate the input gear thrust bearing washer with J 36850 or equivalent.
26. Install the input gear thrust bearing washer.
27. Install the retaining ring for the planetary gear shaft.
28. Install the planetary gear carrier.
29. Install the outer retaining ring tor the input gear bearing.
30. Install new shift fork pads, if removed.
31. Install the range shift sleeve in the range fork.
32. Align the range shift sleeve on the planetary carrier.
33. Align the roller on the range fork in the control actuator lever slot.
34. Install the range shift fork.
Important: Install the shift fork shaft in the range fork assembly with the machined hole facing the bottom of the front case half.
35. Install the shift fork shaft.
36. Install the clutch lever.
Notice: Refer to Fastener Notice in Service Precautions.
Important: When performing the following service procedure, ensure that the clutch lever pivot pins are tightened evenly. Ensure that the clutch lever moves freely after the pivot pins are tightened and engaging the lever.
37. Install the clutch lever pivot pins in the front case half.
^ Tighten the clutch lever pivot pins to 40 Nm (30 ft. lbs.).
Important: Ensure that the shift detent plunger is seated correctly on the control actuator lever.
38. Install the shift detent plunger.
39. Install the shift detent spring.
40. Lightly lubricate a NEW shift detent plunger O-ring seal with transfer case fluid.
41. Install the O-ring seal on the shift detent spring bolt.
42. Install the shift detent spring bolt in the front transfer case.
^ Tighten the shift detent spring bolt to 17 Nm (13 ft. lbs.).
Important: The following service procedure is to be performed only if the rear output shaft is new.
43. Install the rear output shaft oil restrictor flush with the end of the shaft.
44. Install the clutch housing bearing, using the of 8092 (1) and the J 36370 (2).
45. Install the clutch housing on the rear output shaft.
Important: It replacing a 1st design clutch hub or 1st design clutch pressure plate with 2nd design components, replace both the clutch hub and the clutch pressure plate. The 2nd design components have different dimensions than the 1st design. The clutch will not function properly if both components are not the same design level.
46. Install the 1st design (2) or 2nd design (1) clutch hub.
47. It 1st design, install the clutch hub oil restrictor plate.
48. If 1st design, install the clutch pressure plate inner in the clutch housing, with the notch in the plate facing down.