Manual Shift

Before assembling transfer case unit, lubricate all components with clean automatic transmission fluid, Dexron II or equivalent. Remove all dirt or metal chips from rear cover and base bolt holes.

1. Install input shaft and front output shaft bearings.
2. Drive front output shaft seal into case.
3. Install front output shaft through the lower bearing. The front output shaft is held in place in the case by the front output yoke and oil seal slinger assembly. Install front yoke assembly into front output shaft then the rubber seal, flat washer and locknut.
4. Press power take off drive gear onto input shaft assembly.
5. Press needle bearing and bushing into output shaft.
6. Install ring gear into case slot. Retain gear using large snap ring. Ensure snap ring is properly installed.
7. Install input shaft and carrier assembly into case, through input shaft bearing. Do not damage gear teeth when aligning input shaft with ring gear teeth.
8. While supporting the carrier assembly in position, install a new snap ring onto front side of the input shaft bearing. Ensure it is completely seated in the snap ring groove of the input shaft.
9. Install upper input shaft oil seal into the case.
10. Install a new shifter shaft seal into case.
11. Assemble shift cam assembly into case by sliding the shift shaft and lever assembly through the case and seal into engagement with the shift cam. Secure shift cam with retaining clip.
12. Install shift cam assist spring in shift cam bushing.
13. Assemble pump and output shaft as follows:
a. Place oil pump cover with the word Top facing the front of the front case.
b. Install two pins with flats facing upward and spring between pins, then place assembly in the oil pump bore in the output shaft.
c. Place oil pump body and pickup tube over the shaft, ensuring that the pins are riding against the inside of the pump body.
d. Place oil pump rear cover with the words Top Rear facing rear of the case.
e. The word Top on the front cover and rear cover should be on the same side.
f. Install the pump retainer with tabs facing front of transfer case.
g. Install four retaining bolts and rotate the output shaft while tightening the bolts to prevent the pump from binding.
h. Torque the bolts to 35-40 inch lbs. Lubricate assembly with automatic transmission fluid. The output shaft must turn freely within the oil pump. If binding occurs, loosen the four bolts and tighten again.
14. Install high/low shift hub.
15. Install high/low shift fork by engaging it with the shift hub flange and rotating until the roller is engaged with the lower groove of the flange.
16. Install shift rail through the high/low fork bore and into the rail bore in case.
17. Install output shaft and oil pump assembly into input shaft. Ensure external splines of the output shaft engage the internal splines of the high/low shift hub. Ensure the oil pump retainer and oil filter leg are in the groove and notch of the front case. Install the collector magnet into front case notch.
18. Assemble upper and lower sprockets with the chain and place them as an assembly over the upper and lower output shafts. Install washer and snap ring which retain the lower sprocket to the front output shaft.
19. Assemble the 2W-4W lock-up assembly by installing tapered compression spring into lock-up collar with the small end installed first. Place lock-up hub over spring and compress the spring while installing internal snap ring.
20. Install lock-up assembly and shift fork over external splines of upper sprocket and shift rail with long boss of shift rail facing upward.
21. Assemble four wheel drive return spring over shift rail and against shift fork.
22. Place four wheel drive hub over external splines of output shaft and secure using a snap ring. Ensure snap ring is completely seated in the snap ring groove.
23. Press lower output needle bearing into rear cover bore.
24. Press rear output shaft bearing into cover. Install bearing snap ring into cover.
25. Install rear output shaft oil seal into bearing retainer.
26. Coat mating surface of front case with a bead of non-acidic silicone.
27. Place cover onto case. Ensure lower output shaft, shift shaft and shift rail are properly aligned. Install and torque the twelve No. 50 Torx head case to cover attaching bolts to 22-36 ft. lbs.
28. Install rear bearing snap ring onto output shaft. Ensure snap ring is completely seated on output shaft groove.
29. Place speedometer drive gear over shaft with slot aligned with drive ball hole. The gear should go completely against the snap ring which retains the output shaft. Place ball into hole and pull speedometer gear over the ball. Snap retaining clip between snap ring and speedometer gear.
30. Apply a bead of non-acidic silicone sealer to rear bearing retainer or rear slip yoke extension housing face.
31. Place rear bearing retainer or rear slip yoke extension housing in its position and secure with four Torx head attaching bolts. Torque bolts to 22-36 ft. lbs.
32. On models equipped with slip yoke rear bearing retainer housing, remove extension oil seal and bushing. Install new oil seal and bushing.
33. Install rear output shaft yoke and slinger assembly onto rear splines of output shaft. Install rubber seal, flat steel washer and locknut onto output shaft. Torque locknut to 150-180 ft. lbs.
34. Install drain plug and torque to 14-22 ft. lbs.
35. Install four wheel drive indicator light switch and washer into case.
36. Fill transfer case with specified fluid.