Part 2

5. Install the clutch gear (2)(Figure 23) onto the output shaft (1). Verify that the pointed ends of the clutch gear teeth are pointing to the front of the mainshaft.










6. Lubricate sector shaft with transmission fluid and install shift sector (1)(Figure 24) in case. Position slot in sector so it will be aligned with shift fork pin when shift forks are installed.
7. Apply Loctite(TM) 242, or equivalent, to the threads of the sector support to replenish the factory applied patch. Install the shift sector support. Tighten the sector support with Socket to 27-34 Nm (20-25 ft.lbs.).










8. Assemble and install range fork (2) and hub (1)(Figure 25). Be sure hub is properly seated in low range gear and engaged to the input gear.
9. Align and insert range fork pin in shift sector slot.










10. Install mode fork (2) and shift rail (1) onto the mode sleeve.
11. Install the mode fork (2), sleeve (3), and shift rail (1)(Figure 26) into the transfer case.










12. Install mainshaft (2) into the transfer case (1)(Figure 27). Guide mainshaft through the mode and range sleeves and into the input gear.










13. Install the transfer case position sensor or switch (2)(Figure 28). Tighten the sensor or switch to 20-34 Nm (15-25 ft. lbs.) torque.










14. Install manual shift lever (3)and spacer onto sector shaft (1)(Figure 29).
15. Install washer and nut on sector shaft to secure shift lever. Apply 1-2 drops Mopar(R) Lock N' Seal, or equivalent, to nut threads before installation. Then tighten nut to 27-34 Nm (20-25 ft. lbs.) torque.










16. Install new o-ring (1) on detent plug (2)(Figure 30).










17. Install detent plunger (4), spring (3), and plug (2)(Figure 31). Tighten the plug to 16-25 Nm (12-18 ft. lbs.).

FRONT OUTPUT SHAFT AND DRIVE CHAIN










1. Install the front output shaft (2)(Figure 32) into the front output shaft front bearing.










2. Install the front output shaft bearing inner snap-ring (2)(Figure 33) onto the output shaft.
3. Install the new front output shaft seal with Seal Installer










4. Insert front drive sprocket in drive chain.
5. Install drive chain around rear drive sprocket.
6. Position rear drive sprocket (3)(Figure 34) over the output shaft and lower the sprocket and chain assembly until the front sprocket is positioned over the front output shaft.
7. Align the splines in the sprockets to the splines on the output shafts and install the sprockets onto the output shafts.










8. Install front sprocket retaining ring (3)(Figure 35).










9. Install rear sprocket retaining ring (3)(Figure 36).










10. Install spring (2) onto shift rail (1)(Figure 37).










11. Insert magnet (1) in front case pocket (2)(Figure 38).

REAR CASE










1. Install the oil pick-up tube and screen into the rear case half.
2. 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.
3. Align mainshaft with he rear output shaft bearing and align shift rail with bore in rear case. Then install rear case (2)(Figure 39). Verify that the case alignment dowels correctly seat into their mating recesses.










4. Install 4-5 rear case (2) -to- front case (1) bolts (3)(Figure 40) 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.











5. Tighten bolts to 27-34 Nm (20-25 ft. lbs.),
6. Install rear output bearing inner snap-ring (3)(Figure 41) to output shaft (1).

OIL PUMP AND REAR EXTENSION










1. Install the oil pump (3)(Figure 42) onto the output shaft (2).










2. Engage the oil pump pick-up tube (2)(Figure 43) into the oil pump (1). Verify that the pick-up tube o-ring is on the tube and is correctly installed to the oil pump.










3. 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.
4. Install extension housing (2)(Figure 44) onto the rear case half (1).










5. Install rear extension bolts (2)(Figure 45). Tighten the bolts to 27-34 Nm (20-25 ft.lbs.).










6. Install the extension housing boot and seal assembly with Seal Installer (3) and Universal Handle (2)(Figure 46).










7. Install the front companion flange onto the front output shaft.
8. Install two bolts 180° apart into the front output shaft companion flange.
9. Place holder (1)(Figure 47) over the bolts (2) and against the companion flange.
10. Install a new front companion flange nut. Tighten the companion flange nut to 176-271 Nm (130-200 ft.lbs.).