Steps 1 - 30

Transfer Case Assemble

^ Tools Required
- J 8092 Universal Handle
- J 36370 Drive Sprocket Needle Bearing Installer
- J 37668-A Seal Installer
- J 42737 Sector Bearing Installer
- J 42738 Seal Installer
- J 43484 Seal Installer
- J 45380 Transfer Case Rear Bushing Remover and Installer





Important: The following service procedure covers light duty, heavy duty, and super duty versions of this transfer case.
When installing the new retaining rings in any of the following service procedures, ensure that the retaining rings are properly seated before proceeding to the next service procedure. Always use NEW retaining rings.

1. Install the adapter studs to 29.5 - 30.5 mm (1.16 - 1.20 inch) in height, if removed.





2. Using the J 8092 (1) and the J 36370 (2), install the front output shaft rear bearing.





3. Using the J 42737, install the shift detent lever shaft bearing.





4. Install the shift detent lever shaft.





5. Install the shift detent lever shaft retaining ring.





Important: When installing the front input gear bearing, ensure that the groove in the input gear bearing is facing up.

6. Install the input gear bearing.
7. Install the input gear bearing inner retaining ring.





8. Install the front output shaft front bearing.





9. Install the front output shaft front bearing inner retaining ring.





10. If it is a new shaft, or if the cup plug was removed, install the cup plug in the front output shaft, using a suitable driver. The installed depth of the cup plug is 26.75 mm (1.05 in) from the end of the shaft.





11. Install the front output shaft assembly.





12. Install the front output shaft front bearing outer retaining ring.





13. Install the planetary carrier thrust washer.





14. Install the needle bearing in the input gear, using the J8092 (1) and the J45383 (2). Use the large diameter of the tool to install the bearing.





15. Install the input gear in the planetary carrier.
16. Ensure the input gear turns freely. If the input gear does not turn freely, inspect for debris.





17. Install the planetary carrier front thrust washer.





Important: When installing the lock plate, ensure that the letter "E" stamped on the lock plate is facing up.

18. Install the planetary carrier lock plate.





19. Install the retaining ring for the input gear.





20. Install the high/low planetary carrier.





21. Install the outer retaining ring for the input gear bearing.





22. Assemble the high/low shift fork assembly.





23. Install the high/low shift fork on the high/low range collar.





24. Install the high/low range collar with the shift fork to the planetary carrier.





25. Mount the rear output shaft in a soft-jaw vise with the input end up.
26. Install the drive sprocket sleeve on the rear output shaft.
27. Install the drive sprocket front retaining ring.





28. If disassembled, assemble the synchronizer assembly.
28.1. Install the inserts (7) in the hub (6)
28.2. Install the insert springs (5 and 8). Ensure the hooked end of the spring is located in an insert slot.
28.3. Install the synchronizer sleeve (4) on the synchronizer hub (6). The sleeve with the taper and groove end aligns to the shorter side teeth of the hub.





29. Install the synchronizer rings on the rear output shaft. Align the tabs of the outer ring with the slots in the inner ring.
29.1. Install the inner ring
29.2. Install the middle ring
29.3. Install the outer ring
29. Install the synchronizer assembly.
^ The taper or groove end of the synchronizer sleeve faces toward the input end of the rear output shaft.
^ The outer synchronizer ring tabs align to the synchronizer hub.





30. Install the synchronizer retaining ring. Ensure the retaining ring is fully seated in the groove.