Part 1
Transfer CaseAssembly (Steps 1-29)
NOTE: Prior to assembly, lubricate all parts with multi-purpose 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 6 bolts.
^ Tighten to 34 Nm (25 ft. lbs.)
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. CAUTION: The oil pump spring pin must be installed at the correct height to make sure that the oil pump shaft rotates with the rear output shaft.
NOTE: If a measurement was not taken during disassembly, install the pin to the correct height specification using a micrometer.
Press the pin into the rear output shaft pin hole to the previously measured height.
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 multi-purpose transmission fluid.
22. Install the rear output shaft and the pump assembly.
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. Slide the spacer and the torsion spring on the shift shaft and position it beneath the drive tang.
