Assembly

ASSEMBLY

BEARINGS AND SEALS





1. Remove the input shaft bearing snap-ring from the front case half with suitable snap-ring pliers.
2. Remove the input shaft bearing from the front case half with Bearing Remover/Installer 6953 (3) and Universal Handle C-4171 (2).




3. Install the input shaft bearing into the front case half with Bearing Cup Installer 8151 (3) inverted on Universal Handle C-4171 (2).
4. Install the input shaft bearing snap-ring into the front case half with suitable snap-ring pliers.




5. Remove the front output shaft front bearing snap-ring from the front case half.
6. Using Bearing Remover/Installer 6953 (3) and Universal Handle C-4171 (2), remove the front output shaft front bearing.




7. Start front output shaft front bearing in case. Then seat bearing with Seal Installer 8891 (2).
8. Install front output shaft bearing retaining ring.




9. 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.
10. Install new pilot bearing with Pilot Bearing Installer 9035.




11. Remove the front output shaft rear bearing with the screw and jaws from Remover L-4454 (2) and Cup 8148 (3).




12. Install new bearing with Universal Handle C-4171 (2) and Bearing Installer 8128 (3).




13. The bearing bore is chamfered at the top. Install the bearing so it is flush (1) with the lower edge of this chamfer (2).




14. Remove seal from oil pump with suitable pry tool.
15. Install new seal in oil pump with Seal Installer 7888 (2).




16. Remove the rear output shaft bearing (2) snap-ring (3) from the rear case half (1).




17. Remove the rear output shaft bearing from the rear case (1) using Seal Installer 7888 (2).




18. Install the rear output shaft bearing into the rear case (1) using Seal Installer 8152 (3) and Universal Handle C-4171 (2).
19. Install the rear output shaft bearing snap-ring into the rear case half.

INPUT AND PLANETARY GEAR





1. Lubricate gears and thrust washers with recommended transmission fluid.
2. Install bottom thrust washer (2) in low range gear planetary (1). Be sure washer tabs are properly aligned in gear notches.




3. Install input gear (1) in low range gear (2). Be sure input gear is fully seated.




4. Install remaining thrust washer (2) in low range gear and on top of input gear (1).




5. Install retainer (2) on input gear (1).




6. Install snap-ring (2).




7. Align and install low range/input gear assembly (2) in front case (1). Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing.




8. Install snap-ring (2) to hold input/low range gear (1) into front bearing.
9. Install a new input gear oil seal with Seal Installer 9036 and Universal Handle C-4171.

SHIFT FORKS AND MAINSHAFT





1. Lubricate mainshaft splines with recommended transmission fluid.
2. Coat the interior of the drive sprocket hub with ATF+4 and install the drive sprocket drive hub (2) onto the mainshaft (1).




3. Install the mode hub (2) onto the mainshaft (1).




4. Install the mode hub (2) retaining ring (3) onto the mainshaft (1).




5. Install the clutch gear (2) 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) 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 9033 to 27-34 Nm (20-25 ft.lbs.).




8. 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.
9. Align and insert range fork pin in shift sector slot.




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




12. Install new O-ring (1) on detent plug (2).




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




14. Position the shift motor and mode sensor assembly (2) onto the transfer case (1).




15. 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.).




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

FRONT OUTPUT SHAFT AND DRIVE CHAIN





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




2. Install the front output shaft bearing inner snap-ring (2) onto the output shaft.
3. Install the new front output shaft seal with Seal Installer MB991168A.




4. Insert front drive sprocket (3) in drive chain (2).
5. Install drive chain around rear drive sprocket.
6. Position rear drive sprocket 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 (2) retaining ring (3).




9. Install rear sprocket (2) retaining ring (3).




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

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 the rear output shaft bearing and align shift rail with bore in rear case. Then install rear case (2). 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) 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) to output shaft (1).

OIL PUMP AND REAR EXTENSION





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




2. Engage the oil pump pick-up tube (2) 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) onto the rear case half (1).




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




6. Install the extension housing dust boot and seal assembly with Seal Installer 9037 (3) and Universal Handle C-4171 (2).




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) 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.).