Part 2
INPUT GEAR/LOW RANGEFig. 63:
1. Assemble low range gear, input gear thrust washers, input gear and input gear retainer.
Fig. 64:
2. Install low range gear snap ring.
3. Lubricate input gear and low range gears with automatic transmission fluid.
4. Start input gear shaft into front case bearing.
5. Press input gear shaft into front bearing.
Fig. 65:
6. Install new input gear snap ring.
7. Apply 3 mm (1/8 inch) wide bead of MOPAR gasket maker or silicone adhesive sealer to seal surface of front bearing retainer.
Fig. 66:
8. Install front bearing retainer. Tighten retainer bolts to 16 ft. lbs. (21 Nm) torque.
SHIFT FORKS AND MAINSHAFT
Fig. 67:
1. Install new sector shaft O-ring and bushing.
2. Install shift sector.
Fig. 68:
3. Install new pads on low range fork, if necessary.
4. Assemble low range fork and hub.
Fig. 69:
5. Position low range fork and hub in case. Be sure low range fork pin is engaged in shift sector slot.
Fig. 70:
6. Install first mainshaft bearing spacer on mainshaft.
7. Install bearing rollers on mainshaft. Coat bearing rollers with generous quantity of petroleum jelly to hold them in place.
8. Install remaining bearing spacer on mainshaft. Do not displace any bearings while installing spacer.
Fig. 71:
9. Install differential. Do not displace mainshaft bearings when installing differential.
Fig. 72:
10. Install differential snap-ring.
Fig. 73:
11. Install intermediate clutch shaft.
Fig. 74:
12. Install clutch shaft thrust washer.
13. Install clutch shaft snap-ring.
Fig. 76:
14. Inspect mode fork assembly. Replace pads and bushing if necessary. Replace fork tube if bushings inside tube are worn or damaged. Also check springs and slider bracket. Replace worn, damaged components.
Fig. 77:
15. Install mode sleeve in mode fork. Then install assembled sleeve and fork on mainshaft. Be sure mode sleeve splines are engaged in differential splines.
Fig. 78:
16. Install mode fork and mainshaft assembly in case. Rotate mainshaft slightly to engage shaft with low range gears.
17. Rotate mode fork pin into shift sector slot.
Fig. 79:
18. Install shift rail. Be sure rail is seated in both shift forks.
19. Rotate shift sector to align lockpin hole in low range fork with access hole in case.
Fig. 80:
20. insert an easy-out in range fork lockpin to hold it securely for installation. Lockpin is slightly tapered on one end. Insert tapered end into fork and rail.
21. Insert lockpin through access hole and into shift fork. Then remove easy-out and seat the pin with pin punch.
22. Install plug in lockpin access hole.
Fig. 81:
23. Install detent plunger, detent spring and detent plug in case.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
Fig. 82:
1. Install front output shaft.
2. Install drive chain. Engage chain with front output shaft sprocket teeth.
3. Install drive sprocket. Engage drive sprocket teeth with chain. Then engage sprocket splines with mainshaft splines.
Fig. 83:
4. Install drive sprocket snap-ring.
OIL PUMP AND REAR CASE
Fig. 84:
1. Insert oil pickup tube in oil pump and attach oil screen and connector hose to pickup tube. Then install assembled pump, tube and screen in rear case. Be sure screen is seated in case slot as shown.
Fig. 85:
2. Install magnet in front case pocket.
3. Apply 3 mm (1/8 inch) wide bead of MOPAR gasket maker or silicone adhesive sealer to seal surface of front case.
4. Align and install rear case on front case. Be sure case locating dowels are in place and that mainshaft splines are engaged in oil pump inner gear.
5. Install and tighten front case-to-rear case bolts to 41 Nm (30 ft. lbs.) torque. Be sure to install a washer under each bolt used at case dowel locations.
REAR RETAINER
Fig. 86:
1. Install rear bearing O.D. retaining ring with snap-ring pliers. Be sure retaining ring is fully seated in retainer groove.
2. Apply bead of MOPAR Sealer P/N 82300234, or Loctite Ultra Gray, to mating surface of rear retainer. Sealer bead should be a maximum of 3/16 inch
3. Install rear retainer on rear case. Tighten retainer bolts to 20-27 Nm (15-20 ft. lbs.) torque.
Fig. 87:
4. Install new output shaft bearing snap-ring. Lift mainshaft slightly to seat snap-ring in shaft groove, if necessary.
5. Apply 3 mm (1/8 inch) wide bead of MOPAR gasket maker or silicone adhesive sealer to mounting surface of extension housing. Allow sealer to set-up slightly before proceeding.
6. Install extension housing on rear retainer.
7. Install extension housing bolts and tighten to 35-46 Nm (26-34 ft. lbs.).
FRONT YOKE AND SWITCH
1. Install indicator switch in front case. Tighten switch to 20-34 Nm (15-25 ft. lbs.) torque.
2. Lubricate yoke hub with transmission fluid and install yoke on front shaft.
3. Install new seal washer on front shaft.
4. Install yoke on front shaft. Secure yoke with new nut.