Assembly
AssemblyNOTE: Prior to assembly, lubricate all parts with MERCON Multi-Purpose (ATF) Transmission Fluid.
1. Using the special tools and a suitable press, install the bearing.
2. Install the snap ring.
3. Using the special tool, install the oil seal.
4. CAUTION: Do not crush the needle bearing.
Using the special tools and a suitable press, install the needle bearing.
5. Using the special tools and a suitable press, install the sleeve bearing.
6. NOTE: The recessed face of the sun gear must face the rear of the transfer case.
Install the sun gear, the thrust plate, and the snap ring.
7. NOTE: The stepped face of the thrust washer must face upward.
Install the input shaft assembly and the thrust washer.
8. NOTE: Install the bearing on the input shaft assembly so that the snap ring groove in the bearing is closest to the top of the planet carrier.
Using a suitable press, install the bearing.
9. Install the snap ring.
10. Using the special tool, install the oil seal.
11. Install the large snap ring in the groove in the front adapter.
12. CAUTION: Install the front adapter within 15 minutes of applying the silicone sealant or it will be necessary to apply new sealant. If possible, allow one hour before filling the transfer case with lubricant to allow the silicone sealant to cure.
Apply a 3-mm (1/8-inch) bead of silicone sealant to the front adapter mounting surface of the transfer case.
13. Position the front adapter on the transfer case, and install the six bolts.
14. Install the input shaft assembly and the complete carrier assembly as an assembly.
- Align the pinion gears gear teeth and the ring gear teeth. Expand the snap ring and push inward on the planet carrier until the input shaft assembly seats fully in the front adapter. Verify that the snap ring engaged the assembly by holding the front adapter and lightly tapping the face of the input shaft assembly against a wooden block.
15. Attach the front case to the special tool.
16. Install the new shift fork facings. Verify that they snap securely into place.
17. Install the reduction hub and the reduction fork assembly as an assembly.
18. NOTE: Do not remove the plastic insert from the bore of a new pump assembly. Discard it after it slides out of the bore during the pump assembly installation on the rear output shaft.
Install the pump assembly on the rear output shaft.
- Align the keyway in the cover and the spring pin in the rear output shaft and fully seat the pump assembly on the shaft. The shaft will rotate freely in the pump assembly when the pump assembly is fully seated.
19. If the pump assembly does not turn freely, realign the keyway and the spring pin and jiggle the pump assembly until it seats fully and rotates freely on the shaft.
20. Prime the pump assembly.
- Submerge the pump in a container full of clean MERCON Multi-Purpose (ATF) Transmission Fluid.
21. Install the rear output shaft and the pump assembly.
22. Install the oil strainer and the magnet in the slot in the case.
23. Install the front output shaft assembly.
24. Install the snap ring.
25. Install the drive chain, the drive sprocket and the driven sprocket as an assembly.
26. Install the spacer and the snap ring.
27. Install the shift rail through the reduction shift fork. Verify that the shift rail seats in the case bore.
28. Slide the spacer and the torsion spring on the shift shaft and position it beneath the drive tang.
29. WARNING: Keep fingers away from spring ends. Failure to follow these instructions can result in personal injury.
Position the first spring tang to the left of the drive tang.
30. WARNING: Keep fingers away from spring ends. Failure to follow these instructions can result in personal injury.
Wind the second spring tang clockwise past the drive tang, and push the torsion spring and sleeve in as far as it will go.
31. Install the electric shift cam, and slide the drive tang between the torsion spring tangs as far as it will go.
32. CAUTION: Do not bend the cam during installation. This will damage the pin on the end of the shift shaft.
Install the pin on the end of the shift shaft into the hole in the case.
33. Position the torsion spring tangs so that they point toward the top side of the case and just touch the reduction shift fork.
34. Assemble the lockup assembly.
35. Press downward on the lockup hub and install the snap nag.
36. Install the lockup fork and the lockup collar as an assembly.
37. NOTE: After the lockup fork is released, verify that the cam roller is resting on the top surface of the electric shift cam and not into an inside track.
The triangular shaft will be in the two-wheel high (2H) position at final assembly.
38. Lift upward on the lockup fork slightly while holding down on the shift rail and rotate the electric shift cam track into the cam roller by turning the shift shaft.
39. Install the shift collar hub and the return spring.
40. CAUTION: Do not crush the needle bearing.
Using the special tools and a suitable press, install the needle bearing.
41. Using the special tools and a suitable press, install the bearing.
42. Install the snap ring that retains the bearing to the transfer case cover.
43. Using the special tool, install the oil seal.
44. CAUTION: Assemble the cases within 15 minutes of applying the silicone sealant or it will be necessary to apply new sealant. If possible, allow one hour before filling the transfer case with lubricant to allow the silicone sealant to cure.
Apply a 3-mm (1/8 inch) bead of silicone sealant to the mating surface of the front case.
45. Assemble the cases.
- Align the output shaft, the shift shaft, and the return spring to their respective bores in the transfer case cover.
46. Install the bolts.
47. Install the bolts.
48. Install the spacer on the rear output shaft.
49. Using the special tool, install the oil seal.
50. CAUTION: Align the index marks.
NOTE: Be sure the oil seal is not on the shaft before installing the shaft.
Position the flange on the rear output shaft. If necessary, reseat the oil seal in the flange.
51. Install a new oil seal in the flange.
52. Using the special tool, install the flange. Tighten the nut on the special tool to 54 Nm (40 ft. lbs.) to seat the flange on the shaft.
53. Use the special tool to prevent the flange from turning. Install a new washer and a new nut.
54. If the shift shaft will not stay in the 4H position, rotate the shift shaft clockwise to the 2H position. During motor assembly and connector installation, rotate the motor assembly counterclockwise until the motor assembly aligns with the mounting holes.
55. CAUTION: Install the motor assembly within 15 minutes of applying the silicone sealant or it will be necessary to apply new sealant. If possible, allow one hour before filling the transfer case with lubricant to allow the silicone sealant to cure.
Apply a thin coat of silicone sealant to the base of the motor housing.
56. Install the motor assembly and connector.
57. Install the transfer case.