Assembly
ASSEMBLYLubricate transfer case components with Mopar ATF +4, Automatic Transmission Fluid or petroleum jelly (where indicated) during assembly
BEARINGS AND SEALS
CAUTION: The bearing bores in various transfer case components contain oil feed holes. Make sure replacement bearings do not block the holes.
1. Remove the front output shaft seal (1) from case with pry tool (2).
2. Remove bearing retaining ring with screwdriver.
3. Remove bearing with Universal Handle C-4171 (2) and Bearing Installer 5065 (3).
4. Install front output shaft front bearing in case with Universal Handle C-4171 (1) and Bearing Installer 5064 (2).
5. Install output shaft front bearing retaining ring (1). Start ring into place by hand. Then use small screwdriver to work ring into case groove. Be sure ring is fully seated before proceeding.
6. Install new front output seal in front case with Seal Installer 8143-A (1) as follows:
a. Place new seal on tool. Garter spring on seal goes toward interior of case.
b. Start seal in bore with light taps from hammer. Once seal is started, continue tapping seal into bore until installer tool bottoms against case.
7. Remove the output shaft rear bearing with the screw and jaws from Remover L-4454 (2) and Cup 8148 (3).
8. Install new bearing with Universal Handle C-4171 (1) and Bushing Installer 5066 (3).
9. The bearing bore is chamfered at the top. Install the bearing (1) so it is flush with the lower edge of this chamfer (2).
10. Using Seal Installer C-4210 (2) and Universal Handle C-4171 (1), drive input shaft bearing from inside the annulus gear opening in the case.
11. Install locating ring on new bearing.
12. Position case so forward end is facing upward.
13. Using Seal Installer C-4210 and Universal Handle C-4171, drive input shaft bearing into case. The bearing locating ring (1) must be fully seated against case surface.
14. Remove input gear pilot bearing by inserting a suitably sized drift (1) into the splined end of the input gear (2) and driving the bearing out with the drift and a hammer.
15. Install new pilot bearing with Bearing Installer 5065 (2) and Universal Handle C-4171 (1).
16. Remove front bearing retainer seal with suitable pry tool.
17. Install new front bearing retainer (1) with Seal Installer 7884 (2).
18. Remove seal from oil pump housing with a suitable pry tool
19. Install new seal (1) in oil pump housing (3) with Seal Installer 7888 (2).
20. Remove rear retainer bearing with Bearing Installer 5065 and Universal Handle C-4171.
21. Install rear bearing in retainer (3) with Universal Handle C-4171 (1) and Bearing Installer 5064 (2).
INPUT AND LOW RANGE GEAR
1. Lubricate gears (3, 4) and thrust washers (5) with recommended transmission fluid.
2. Install first thrust washer (5) in low range gear (4). Be sure washer tabs are properly aligned in gear notches.
3. Install input gear (3) in low range gear (4). Be sure input gear is fully seated.
4. Install remaining thrust washer in low range gear and on top of input gear. Be sure washer tabs are properly aligned in gear notches.
5. Install retainer on input gear and install snap-ring.
INPUT GEAR AND LOW RANGE GEAR
1. Align and install low range/input gear assembly (2) in front case. Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing.
2. Install snap-ring (2) to hold input/low range gear (1) into front bearing.
3. Clean gasket sealer residue from retainer and inspect retainer for cracks or other damage.
4. Apply a 3 mm (1/8 inches) bead of Mopar Gasket Maker, or equivalent silicone adhesive, to sealing surface of retainer.
5. Align cavity in seal retainer with fluid return hole in front of case.
CAUTION: Do not block fluid return cavity on sealing surface of retainer when applying Mopar Gasket Maker, or equivalent silicone adhesive sealer. Seal failure and fluid leak can result.
6. Install bolts to hold retainer (1) to transfer case. Tighten to 16 - 25 Nm (12 - 18 ft. lbs.) of torque.
MAINSHAFT
1. Lubricate mainshaft splines with recommended transmission fluid.
2. Slide drive sprocket onto mainshaft.
3. Slide mode hub onto mainshaft.
4. Install mode hub retaining ring. Verify that the retaining ring is fully seated in mainshaft groove.
SHIFT FORKS AND MAINSHAFT
1. Install new sector shaft 0-ring.
2. Install shift sector (1) in case. Lubricate sector shaft with transmission fluid before installation.
3. Assemble and install range fork (2) and hub (1). Be sure hub is properly seated in low range gear and engaged to the input gear.
4. Align and insert range fork pin in shift sector slot.
5. Install assembled mainshaft (3). Be sure shaft is seated in pilot bearing and input gear.
6. Install new pads on mode fork if necessary.
7. Insert mode sleeve (1) in mode fork. Be sure long side of sleeve is toward long end of shift rail (2).
8. Install assembled mode fork and sleeve (1). Be sure fork rail goes through range fork and into case bore. Also be sure sleeve is aligned and seated on mainshaft hub.
9. Rotate sector to NEUTRAL position.
10. Install new O-ring (2) on detent plug (3).
11. Lubricate detent plunger with transmission fluid or light coat of petroleum jelly
12. Install detent plunger (1), spring (4), and plug (3).
13. Verify that plunger is properly engaged in sector.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Lubricate front output shaft-sprocket assembly, drive chain and drive sprocket with transmission fluid.
2. Assemble drive chain (2) and front output shaft (1).
3. Start chain on mainshaft drive sprocket.
4. Guide front shaft into bearing and drive sprocket onto mainshaft drive gear.
5. Install mode spring (1) on upper end of mode fork shift rail.
OIL PUMP AND REAR CASE
1. Install magnet in front case pocket (1).
2. Assemble oil pickup screen, connecting hose, and tube.
3. Install new pickup tube 0-ring (2) in oil pump (1).
4. Insert oil pickup tube (2) in oil pump inlet.
5. Position assembled oil pump and pickup tube in rear case. Be sure pickup screen is securely seated in case slot. Also be sure oil pump locating tabs are outside rear case.
6. Apply 3 mm (1/8 inches) wide bead of Mopar Gasket Maker, or equivalent silicone adhesive sealer, to mounting flange of front case. Work sealer bead around bolt holes.
7. Lift rear case and oil pump and carefully position assembly on front case. Be sure case dowels are aligned and that mode fork rail extends through rear case before seating rear case on front case.
8. Install case attaching bolts. Alignment bolts at each end of case are only ones requiring washers (1).
9. Tighten case bolts to 27 - 34 Nm (20 - 25 ft. lbs.) torque.
COMPANION FLANGE AND SHIFT MOTOR AND MODE SENSOR ASSEMBLY
CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar Lock & Seal or Loctite 242 to replenish the lock patch material originally found on the bolts
1. Position the shift motor and mode sensor assembly (2) onto the transfer case.
2. Install the bolts (3) to hold the shift motor and mode sensor assembly (2) to the transfer case (1). Tighten the bolts to 16 - 25 Nm (12 - 18 ft. lbs.) torque.
3. Install new seal washer (1) onto the front output shaft.
4. Lubricate the companion flange hub with transmission fluid and install the flange onto the front output shaft.
5. Install a new companion flange nut onto the front output shaft.
6. Tighten the flange nut to 122 - 176 Nm (90 - 130 ft. lbs.) torque. Use Spanner Wrench 6958, or similar tool to hold flange while tightening nut.
REAR RETAINER
1. Apply 3 mm (1/8 inches) wide bead of Mopar Gasket Maker, or equivalent silicone adhesive sealer, to mounting surface of rear retainer. Allow sealer to set-up slightly before proceeding.
2. Install rear retainer on rear case. Tighten retainer bolts to 27 - 34 Nm (20 - 25 ft. lbs.).
3. Install new output shaft bearing snap-ring (2). Lift mainshaft slightly to seat snap-ring in shaft groove, if necessary.
4. Apply 3 mm (1/8 inches) wide bead of Mopar Gasket Maker, or equivalent silicone adhesive sealer, to mounting surface of extension housing. Allow sealer to set-up slightly before proceeding.
5. Install extension housing on rear retainer.
6. Install extension housing bolts and tighten to 27 - 34 Nm (20 - 25 ft. lbs.).