Part 2

9. Lubricate sector shaft (1) with transmission fluid and install shift sector in case. Position slot in sector so it will be aligned with shift fork pin when shift forks are installed.










10. Install the shift sector o-ring.
11. 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.
12. Align and insert range fork pin in shift sector slot.
13. Install the range fork retaining ring.









14. Install mode fork and shift rail onto the mode sleeve.
15. Install the mode fork (2), sleeve (1), and shift rail (2) into the transfer case.










16. Install mainshaft (2) into the transfer case front housing (1). Guide mainshaft through the mode and range sleeves and into the input gear.










17. Install new o-ring (1) on detent plug (2).










18. Install detent plunger (4), spring (3), and plug (2). Tighten the plug to 16-24 Nm (12-18 ft. lbs.).

FRONT OUTPUT SHAFT AND DRIVE CHAIN










1. Install the front output shaft (2) into the front output shaft bearing.










2. Install the front output shaft retaining ring (2) onto the output shaft (1).
3. Install the new front output shaft seal with Seal Installer.










4. Insert front sprocket (1) in drive chain (2).
5. Install drive chain (2) around mainshaft sprocket. Then position front sprocket over front shaft.
6. Raise mainshaft about 2.54 cm (one inch) and seat front sprocket on front output shaft.










7. If mainshaft and mode sleeve were unseated during chain installation, align and reseat mainshaft in input gear and hub.
8. Install front sprocket (1) retaining ring (2).










9. Install spring (2) and cup (1) on shift rail.










10. Insert magnet (1) in front case pocket (2).

OIL PUMP AND REAR CASE










Lubricate the oil pump components with transmission fluid before installation. Prime the oil pickup tube by pouring a little oil into the tube before installation.

CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft inner bearing race and will become mis-aligned if the bolts are loosened. If the transfer case failure has generated any debris which may have become trapped in the oil pump. the rear case and oil pump assembly MUST be replaced.

1. Install new o-ring in pickup tube inlet of oil pump.
2. Insert oil pickup tube into the oil pump.
3. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into case interior.
4. Align oil pump with mainshaft and align shift rail with bore in rear case. Then install rear case (1)(Figure 31) and oil pump assembly onto the front case (2).