Assembly

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.

NOTE: Apply a light coating of oil to both the inner lip and outer surface of the new oil seal.

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 2 mm (0.08 in.) bead of MOPAR(R) 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.
24. Using locally acquired nuts, install the 120 mm long bolts through the transfer case and install the nuts to the bolts. Tighten the nuts to 10 Nm (7.5 ft.lbs.). Leave the 120 mm bolts torqued this way for a minimum of 30 minutes to ensure that the sealant has cured properly. After the 30 minutes, the 120 mm bolts can be removed.




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




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




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




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




30. Clean the mating surfaces of the transfer case cover and the rear housing.
31. Apply a 2 mm (0.08 in.) bead of MOPAR(R) Gasket Maker around the perimeter of the rear housing.
32. Position the transfer case cover (1) onto the transfer case (2).




33. 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).




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





NOTE: For the most accurate torque reading, apply a light coating of oil to the nut face that contacts the flange and to the flange splines.

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




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




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