Assembly

Transfer Case - All Wheel Drive (AWD)

Transfer Case Exploded View - Torque On Demand (TOD) (Part 1):

Transfer Case Exploded View - Torque On Demand (TOD) (Part 2):

Assembly
1. Lubricate all internal components with the recommended transfer case lubricant during reassembly.
2. Clean the mating surfaces of the cases.
3. Using the special tools, install the input shaft support bearing.





4. Using the special tools, install the front output shaft bearing.





5. Using the special tool, install the front yoke-to-flange seal.





6. Using the special tool, install a new rear output seal.





7. Install the dust shield, if removed.





8. Install the front output shaft and snap ring.





9. Using the special tools, install the input seal.





10. Install the rear output shaft sleeve and snap ring.





11. Install the output shaft.





12. Install the oil pump assembly.
^ Make sure the oil pump finger is in the slot in the case.





13. Install the oil pan magnet into its slot in the case.





14. Install the output shaft hub.





15. Install the thrust bearing race.





16. Install the thrust bearing.





17. Install the thrust bearing race.





18. Install the drive chain and the sprockets as an assembly.





19. Install the spacer.





20. Install the clutch pack assembly.





21. Install the snap ring.





22. Install the wave spring.





23. Install the apply cam and the 3 ball bearings.





24. Install the cam/coil housing.





25. Install the snap ring.





26. Using a suitable press and the special tool, install the rear output shaft support bearing.





27. Using a suitable press and the special tool, install the front output shaft rear bearing.





28. Using the special tool, install the rear output shaft bearing.





29. Using the special tool, install the front output shaft bearing.





30. Install the coil.
1 Position the coil.
2 Install the 3 coil nuts.
^ Tighten to 10 Nm (89 lb-in).





31. CAUTION: If too much silicone rubber is used when sealing the cover to the case, the excess sealant can plug the fluid filter and cause case failure.

Apply a small bead of sealant to the mating surfaces of the case and cover.





32. Position the 2 transfer case halves and tighten the 20 transfer case bolts according to sequence shown.
^ Tighten to 24 Nm (18 lb-ft).
33. Lift up on the output shaft and install the rear output shaft snap ring.





34. Apply a small bead of sealant to the transfer case cover and extension housing mating surfaces.





35. Install the extension housing.
1 Position the brown clutch coil wire through its hole in the extension housing.
2 Position the extension housing.
3 Install the 6 extension housing bolts.
^ Tighten to 24 Nm (18 lb-ft).





36. Using the special tool, install the oil seal, if removed.





37. Install the coil wire into the shift motor electrical connector.
1 Install the coil wire and pin.
2 Install the wire connector spacer.





38. Remove the transfer case from the special tool.





39. Install the transfer case in the vehicle.
40. Fill the transfer case.