Assembly

1. Install rear output shaft seal to rear bearing retainer, using seal installer tool No. J-37668, or equivalent.

2. Install front output bearing to front case, using driver handle tool Nos. J-80922 and J-33832, or equivalent.

3. Install front output bearing snap ring and output seal to front case, using seal installer tool No. J-37668, or equivalent.

4. Install rear output bearing to rear case, using driver handle tool No. J-80922, or equivalent.

5. Install input bearing snap ring, then sector detent spring and roller to front case.

6. Install sector shaft through case and align with spline, then connect retainer clip.

7. Install power take-off drive gear, then the input carrier assembly to front case.

8. Install input carrier snap ring to carrier, then the seal to mainshaft on front case using seal installer tool No. J-37668, or equivalent.

9. Install annulus gear and snap ring to front of case.

10. Install range fork and shaft hub, aligning shift hub to carrier assembly and shift fork pin to slot in the sector.

11. Install shift rail through range fork and into boss in front of case.

12. Install mainshaft and oil pump assembly into carrier assembly.

13. Install front output shaft to front output bearing.

14. Assemble drive gear, driven gear and drive chain to mainshaft and front output shaft, then install washer to front output shaft.

15. Install front output snap ring to front output shaft.

16. Install synchronizer assembly, then the mode shift fork aligning synchronizer to mainshaft drive gear and mode fork to shift rail.

17. Place synchronizer hub to assembly.

18. Place clutch housing and snap ring to mainshaft, then install shift rail spring to shift rail.

19. Install clutch coil to rear case, then tighten nuts to clutch coil.

20. Connect clutch coil wire connector to clutch coil wire.

21. Apply RTV sealer, or equivalent, to rear and front case halves, then install case screws. Torque to 23 ft. lbs.

22. Install rear bearing snap ring and tone wheel snap ring to mainshaft.

23. Install new speedometer tone wheel to mainshaft, using suitable installer tool No. J-5590 or equivalent. IRWAL braking system, speedometer, odometer, cruise control and ECM depend on proper operation of speedometer tone wheel. Ensure care is taken not to damage upon installation.

24. Apply RTV sealer of equivalent to rear bearing retainer surfaces.

25. Install rear bearing retainer bolts. Torque to 23 ft. lbs.

26. Install 4WD indicator switch to front case half. Torque to 30 ft. lbs.

27. Install speedometer pickup switch and bolt to rear bearing retainer. Torque to 12 ft. lbs.

28. Install front output flange, rubber sealing washer, flat washer and nut to front output shaft.