Disassembly

DISASSEMBLY





1. Place the transfer case so that it can be drained of any remaining fluid and remove the drain plug (5).





2. Install Holder 6958 (1) onto the rear output flange (2).
3. Remove the output shaft nut.





4. Remove the rear output shaft flange (2) from the output shaft. If the flange is difficult to remove, use a suitable 2 or 3 jaw puller to remove the flange.





5. Install Holder 6958 (1) onto the front output flange (2).
6. Remove the output shaft nut.





7. Remove the front output shaft flange (2) from the output shaft. If the flange (2) is difficult to remove, use a suitable 2 or 3 jaw puller (1) to remove the flange.





8. Remove the bolts (3) holding the transfer case rear cover (2) to the transfer case.





9. Remove the transfer case cover (1) from the transfer case (2).





10. Remove the rear output shaft seal from the transfer case cover with a suitable pry tool.
11. Remove the rear output shaft bearing snap-ring (1) from the transfer case cover (2).
12. Remove the output shaft bearing from the cover using a suitable drift tool.





13. Remove the output shaft (1) from the planetary gear system (2).





14. Remove the snap-ring (2) holding the input shaft (1) to the planetary gear system (3).





15. Remove the planetary gear system (1) from the transfer case rear housing (2).





16. Remove the bolts (1) holding the rear housing (2) to the front housing.





17. Loosen the rear housing (1) from the front housing (2) by prying the sections apart at the provided slots. Remove the rear housing (1) from the front housing (2).





18. Remove the front output shaft (1) from the front housing (2).





19. Remove the intermediate gear (1) from the front housing (2).





20. Remove the input gear and hollow shaft assembly (1) from the front housing (2).





21. Remove the snap-ring (2) holding the input shaft (1) in the hollow shaft (3).





22. Remove the input gear thrust washer (2) from the input shaft (1) and hollow shaft (3).





23. Remove the hollow shaft (2) from the input shaft (1)





24. Install the jaws from Remover L-4518 (2) into the intermediate gear rear bearing race in the rear housing (1).





25. Install the cup from Remover L-4518 (2) onto the jaws. Install the bearing, washer, and nut onto the threaded shaft and remove the bearing race.
26. Repeat Step 24 and Step 25 for the other blind bearing races in the front and rear housings.
27. Drive out the input gear and front output shaft seals with a suitable drift.
28. Drive out the front hollow shaft and front output shaft front bearing races with a suitable brass drift.





29. Remove the front output shaft (2) front bearing with Press C-293-PA (1) and Adapters C-293-52 (3).





30. Remove the front output shaft (4) rear bearing with Press C-293-PA (1), Plug 8513A (2), and Adapters C-293-52 (3).





31. Remove the front hollow shaft (3) bearing with Press C-293-PA (1), Plug 9678 (2), and Adapters C-293-48 (4).





32. Remove the rear hollow shaft (4) bearing with Press C-293-PA (1), Plug SP3289 (2), and Adapters C-293-48 (3).





33. Remove the front and rear intermediate gear (4) bearings with Press C-293-PA (1), Plug 8513A (2), and Adapters C-293-40 (3).

ASSEMBLY





1. Install the intermediate gear rear bearing race into the rear housing (1) with Handle C-4171 (2) and Installer D-130 (3).





2. Install the intermediate gear front bearing race into the front housing (1) with Handle C-4171 (2) and Installer D-130 (3).





3. Install the hollow shaft front bearing race into the front housing (1) with Handle C-4171 (2) and Installer C-4308 (3).





4. Install the hollow shaft rear bearing race into the rear housing (1) with Handle C-4171 (2) and Installer D-145 (3).





5. Install the front output shaft front bearing race into the front housing (1) with Handle C-4171 (2) and Installer D-130 (3).





6. Install the front output shaft rear bearing race into the rear housing (1) with Handle C-4171 (2) and Installer D-130 (3).





7. Install the front output shaft front bearing (2) onto the front output gear (3) with Installer C-3717 (1).





8. Install the front output shaft rear bearing onto the front output gear (3) with Handle C-4171 (1) and Installer L-4410 (2).





9. Install the front and rear bearings onto the intermediate gear (3) with Handle C-4171 (1) and Installer L-4410 (2).





10. Install the front bearing onto the hollow shaft (3) with Handle C-4171 (1) and Installer C-4213 (2).
11. Install the rear bearing onto the hollow shaft with Installer 9679.





12. Install a new front output shaft seal into the front housing with Installer MD998334.
13. Install a new input gear seal in the front housing (1) using Installer 8891 (2).





14. Set the hollow shaft in position in the front housing.
15. Install the input shaft through the front seal and the hollow shaft.
16. Install the input gear thrust washer (2) onto the input shaft (1) and hollow shaft (3).





17. Install the snap-ring (2) to hold the input shaft (1) in the hollow shaft (3).





18. Install the intermediate gear (1) into the front housing (2).





19. Install the front output shaft (1) into the front housing (2).





20. Clean the mating surfaces of the transfer case housings.
21. Apply a 3 mm (0.125 inch) bead of Mopar Gasket Maker around the perimeter of the front housing.
22. Set the rear housing (1) onto the front housing (2).





23. install the bolts (1) to hold the rear housing (2) to the front housing. Tighten the bolts in a cross pattern to 34 Nm (25 ft. lbs.) for the 30 and 45 mm long bolts and 22 Nm (16 ft. lbs.) for the 120mm long bolts.





24. Install the planetary gear system (1) into the transfer case rear housing (2).





25. Install the snap-ring (2) to hold the input shaft (1) to the planetary gear system (3).





26. Install the output shaft (1) into the planetary gear system (2).





27. Install the output shaft bearing into the cover using a suitable drift tool.
28. Install the rear output shaft bearing snap-ring (1) into the transfer case cover (2).





29. Clean the mating surfaces of the transfer case cover and the rear housing.
30. Apply a 3 mm (0.125 inch) bead of Mopar Gasket Maker around the perimeter of the rear housing.
31. Position the transfer case cover (1) onto the transfer case (2).





32. Install the bolts (3) to hold the transfer case rear cover (2) to the transfer case. Tighten the bolts in a cross pattern to 34 Nm (25 ft. lbs).





33. Install the rear output shaft seal from the transfer case cover (2) with Installer C-3860A (1).





34. Install the rear output shaft flange (2) onto the output shaft. Install a new nut.





35. Install Holder 6958 (1) onto the rear output flange (2).
36. Tighten the rear output flange nut to 250 Nm (185 ft. lbs.).





37. Install the front output shaft flange onto the front output shaft. Install a new nut.
38. Install Holder 6958 (1) onto the front output flange (2).
39. Tighten the front output flange nut to 250 Nm (185 ft. lbs.).