Part 2
Transfer CaseAssembly (Steps 30-58)
30. 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.
31. 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.
32. Install the electric shift cam, and slide the drive tang between the torsion spring tangs as far as it will go.
33. 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.
34. Position the torsion spring tangs so that they point toward the top side of the case and just touch the reduction shift fork.
35. Assemble the lockup assembly.
36. Press downward on the lockup hub and install the snap ring.
37. Install the lockup fork and the lockup collar as an assembly.
38. 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 2-wheel high (2H) position at final assembly.
39. 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.
40. Install the shift collar hub and the return spring.
41. CAUTION: Do not crush the needle bearing.
Using the special tools and a suitable press, install the needle bearing.
42. Using the special tools and a suitable press, install the bearing.
43. Install the snap ring that retains the bearing to the transfer case cover.
44. Using the special tool, install the oil seal.
45. 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.
46. Assemble the cases.
^ Align the output shaft, the shift shaft, and the return spring to their respective bores in the transfer case cover.
47. Install the bolts.
^ Tighten to 34 Nm (25 ft. lbs.)
48. Install the bolts.
^ Tighten to 34 Nm (25 ft. lbs.)
49. Install the spacer on the rear output shaft.
50. Using the special tool, install the oil seal.
51. 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.
52. Install a new oil seal in the flange.
53. 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.
54. Use the special tool to prevent the flange from turning. Install a new washer and a new nut.
^ Tighten to 210 Nm (155 ft. lbs.)
55. 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.
56. 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.
57. Install the motor assembly and connector.
^ Tighten to 10 Nm (89 inch lbs.)
58. Install the transfer case.