Part 2
INPUT GEAR/LOW RANGE ASSEMBLY
Low Range And Input Gear Assembly:
1. Assemble low range gear, input, gear thrust washers, input gear and input gear retainer.
Install Low Range Gear Snap Ring:
2. Install low range gear snap ring.
3. Lubricate input gear and low range gears with automatic transmission fluid.
4. Start input gear shaft into front case bearing.
5. Press input gear shaft into front bearing.
Input Gear Snap Ring Installation:
6. Install new input gear snap ring.
7. Apply 3 mm (1/8 inch) wide bead of Mopar (R) gasket maker or silicone adhesive sealer to seal surface of front bearing retainer.
Installing Front Bearing Retainer:
8. Install front bearing retainer. Tighten retainer bolts to 16 ft. lbs. (21 Nm) torque.
SHIFT FORKS AND MAINSHAFT INSTALLATION
Sector O-Ring And Bushing Installation:
1. Install new sector shaft O-ring and bushing.
2. Install shift sector.
Assembling Low Range Fork And Hub:
3. Install new pads on low range fork, if necessary.
4. Assemble low range fork and hub.
Positioning Low Range Fork:
5. Position low range fork and hub in case. Be sure low range fork pin is engaged in shift sector slot.
Installing Mainshaft Bearing Rollers And Spacers:
6. Install first mainshaft bearing spacer on mainshaft.
7. Install bearing rollers on mainshaft. Coat bearing rollers with generous quantity of petroleum jelly to hold them in place.
8. Install remaining bearing spacer on mainshaft. Do not displace any bearings while installing spacer.
Differential Installation:
9. Install differential. Do not displace mainshaft bearings when installing differential.
Installing Differential Snap-Ring:
10. Install differential snap-ring.
Installing Intermediate Clutch Shaft:
11. Install intermediate clutch shaft.
Installing Clutch Shaft Thrust Washer:
12. Install clutch shaft thrust washer.
Installing Clutch Shaft Snap-Ring:
13. Install clutch shaft snap-ring.
Mode Fork Assembly Inspection:
14. Inspect mode fork assembly. Replace pads and bushing if necessary. Replace fork tube if bushings inside tube are worn or damaged. Also check springs and slider bracket. Replace worn, damaged components.
Installing Mode Fork And Sleeve:
15. Install mode sleeve in mode fork. Then install assembled sleeve and fork on mainshaft.
Be sure mode sleeve splines are engaged in differential splines.
Assembled Mainshaft And Mode Fork Installation:
16. Install mode fork and mainshaft assembly in case. Rotate mainshaft slightly to engage shaft with low range gears.
17. Rotate mode fork pin into shift sector slot.
Shift Rail Installation:
18. Install shift rail. Be sure rail is seated in both shift forks.
19. Rotate shift sector to align lockpin hole in low range fork with access hole in case.
Installing Low Range Fork Lockpin:
20. Insert an easy-out in range fork lockpin to hold it securely for installation. Lockpin is slightly tapered on one end. Insert tapered end into fork and rail.
21. Insert lockpin through access hole and into shift fork. Then remove easy-out and seat the pin with pin punch.
22. Install plug in lockpin access hole.
Detent Pin, Spring And Plug Installation:
23. Install detent plunger, detent spring and detent plug in case.
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION
Drive Chain And Sprocket Installation:
1. Install front output shaft.
2. Install drive chain. Engage chain with front output shaft sprocket teeth.
3. Install drive sprocket. Engage drive sprocket teeth with chain. Then engage sprocket splines with mainshaft splines.
Drive Sprocket Snap-Ring Installation:
4. Install drive sprocket snap-ring.
OIL PUMP AND REAR CASE INSTALLATION
Oil Screen And Pickup Tube Installation:
1. Insert oil pickup tube in oil pump and attach oil screen and connector hose to pickup tube. Then install assembled pump, tube and screen in rear case. Be sure screen is seated in case slot as shown.
Installing Case Magnet:
2. Install magnet in front case pocket.
3. Apply 3 mm (1/8 inch) wide bead of Mopar (R) gasket maker or silicone adhesive sealer to seal surface of front case.
4. Align and install rear case on front case. Be sure case locating dowels are in place and that mainshaft splines are engaged in oil pump inner gear.
5. Install and tighten front case-to-rear case bolts to 41 Nm (30 ft. lbs.) torque. Be sure to install a washer under each bolt used at case dowel locations.
REAR RETAINER INSTALLATION
1. Remove rear bearing in retainer using Installer 8128 and Handle C-4171.
Installing Rear Bearing In Retainer:
2. Install rear bearing in retainer with Tools C-4171 and 5064.
Rear Bearing Retaining Ring Installation:
3. Install rear bearing O.D. retaining ring with snap-ring pliers. Be sure retaining ring is fully seated in retainer groove.
4. Apply bead of Mopar (R) Sealer P/N 82300234, or Loctite"TM" Ultra Gray, to mating surface of rear retainer. Sealer bead should be a maximum of 3/16 inch.
5. Install rear retainer on rear case. Tighten retainer bolts to 20 - 27 Nm (15 - 20 ft. lbs.) torque.
6. Install rear bearing I.D. retaining ring and spacer on output shaft.
7. Apply liberal quantity of petroleum jelly to new rear seal and to output shaft. Petroleum jelly is needed to protect seal lips during installation.
Output Shaft Seal And Protector:
8. Slide seal onto Seal Protector 6992. Slide seal protector and seal onto output shaft.
Rear Seal Installation:
9. Slide Installer C-4076-B onto seal protector with the recessed side of the tool toward the seal. Drive seal into rear bearing retainer with installer C-4076-B and handle MD-998323.
10. Install rear slinger with installer C-4076-A and handle MD-998323.
Input Gear And Carrier Components:
11. Install boot on output shaft slinger and crimp retaining clamp with tool C-4975-A.
FRONT YOKE AND SWITCH INSTALLATION
1. Install indicator switch in front case. Tighten switch to 20 - 34 Nm (15 - 25 ft. lbs.) torque.
2. Lubricate yoke hub with transmission fluid and install yoke on front shaft.
3. Install new seal washer on front shaft.
4. Install yoke on front shaft. Secure yoke with new nut.