Assembly
AssemblyNOTE: Prior to assembly, lubricate all parts with MERCON Multi-Purpose (ATF) Transmission Fluid.
1. Using the special tools, press a new bearing into the transfer case.
2. Install the snap ring.
3. Using the special tool, install the oil seal.
4. NOTE: Fill the second groove of the shift shaft with grease, and install a new O-ring.
Install the shift mechanism into the case.
1. Install the shift cam.
2. Install the shift shaft.
3. Install the clip.
4. Install the detent.
5. Install the four-wheel drive switch.
5. After the shift care, shift shaft and C-clip have been installed in the front case and with the shift shaft positioned in the 4H detent position, place the spring roller into part-position on the 90 degree bent tang of the spring and insert the roller into the spring/roller slot of the shift cam. Position the middle section of the spring into the groove of the front case pivot boss and push to lock the upper end of the assist spring behind the front case spring anchor tab.
6. CAUTION: Do not crush the needle bearing.
Using the special tools and a suitable press, install the needle bearing.
7. Using the special tools and a suitable press, install the sleeve bearing.
8. 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.
9. NOTE: The stepped face of the thrust washer must face upward.
Install the input shaft assembly and the thrust washer.
10. 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.
11. Install the snap ring.
12. Using the special tool, install the oil seal.
13. Install the large snap ring in the groove in the front adapter.
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. 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, then position the front adapter on the transfer case, and install the six bolts.
16. Attach the front case to the special tool.
17. Install the new shift fork facings. Verify that they snap securely into place.
18. Install the reduction hub and the reduction fork assembly as an assembly.
19. 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.
20. 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.
21. Prime the pump assembly.
- Submerge the pump in a container full of clean MERCON Multi-Purpose (ATF) Transmission Fluid.
22. Install the rear output shaft and the pump assembly.
- Make sure the external splines of the output shaft engage the internal splines of the lockup hub. Make sure the oil pump retainer arm and the oil filter leg are in the groove and notch of the front case.
23. Install the oil strainer and the magnet in the slot in the case.
24. Install the front output shaft assembly.
25. Install the snap ring.
26. Install the drive chain, the drive sprocket and the driven sprocket as an assembly.
27. Install the spacer and the snap ring.
28. Install the shift rail through the reduction shift fork. Verify that the shift rail seats in the case bore.
29. Assemble the lockup assembly.
30. Press downward on the lockup hub and install the snap ring.
31. Install the lockup fork and the lockup collar as an assembly.
32. The triangular shaft will be in the two-wheel high (2H) position at final assembly.
33. Install the shift collar hub and the return spring.
34. CAUTION: Do not crush the needle bearing.
Using the special tools, press the needle bearing into the housing.
35. Using the special tools, press the bearing into the housing.
36. Install the snap ring that retains the bearing to the transfer case cover.
37. 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.
38. Assemble the cases.
- Align the output shaft, the shift shaft, and the return spring to their respective bores in the transfer case cover.
39. Install the bolts.
40. Install the bolts.
41. Install the spacer on the rear output shaft.
42. Using the special tool, install the oil seal.
43. CAUTION: Align the index marks.
NOTE: Make sure the oil seal is not on the shaft before installing the flange.
Position the flange on the rear output shaft.
44. Install a new oil seal in the flange.
45. Using the special tool, install the flange, the washer and a new nut. Tighten the new nut on the special tool to 54 Nm (40 ft. lbs.) to seat the flange on the shaft.
46. Use the special tool to prevent the flange from turning. Install the new washer and the new nut.
47. Install the transfer case.