Part 3

5. Install 4-5 rear case (1)-to front case (2) bolts (3) to hold rear case in position. Tighten bolts snug but not to specified torque at this time.

CAUTION: Verify that shift rail, and case alignment dowels are seated before installing any bolts. Case could be cracked if shaft rail or dowels are misaligned.

6. Apply Loctite(TM) 242 to remainder of rear case-to-front case bolt threads and install bolts. Tighten bolts to 20-27 Nm (15-24 ft. lbs.).










7. Install rear output bearing (2) snap-ring (3) to output shaft (1).

SEAL BOOT AND SHIFT MOTOR ASSEMBLY

1. Install the front output shaft seal slinger with Installer. Install the slinger onto the shaft until the tool contacts the rear of the output shaft.
2. Install a new seal boot clamp onto the seal boot.
3. Install the seal boot and clamp onto the slinger hub and tighten the clamp with Crimp Tool.









4. Position the shift motor and mode sensor assembly (2) onto the transfer case (1).
5. Install the bolts (3) to hold the shift motor and mode sensor assembly to the transfer case. Tighten the bolts to 16-24 Nm (12-18 ft. lbs.).

REAR EXTENSION










1. Install new seal in rear extension housing seal with Installer and Universal Handle.
2. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of rear extension housing. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess could be displaced into output bearing.
3. Align and install rear extension (1) on the transfer case (2).
4. Apply Mopar(R) Silicone Sealer to threads of rear extension housing bolts. Then install and tighten bolts to 16-24 Nm (12-18 ft. lbs.) torque.