Part 2

ASSEMBLY

FRONT OUTPUT SHAFT AND DRIVE CHAIN










1. Install front output shaft (2) into the font output shaft bearing.










2. Install the front output shaft snap-ring onto the front output shaft.
3. Install new front output seal in front case with Seal Installer 9041 (2) and Universal Handle C-4171 (1).










4. Insert front sprocket (3) in drive chain (2).
5. Install drive chain around mainshaft drive sprocket. Then position front sprocket over front output shaft.
6. Install the mainshaft (1) into the range hub and mode sleeve and seat the front drive sprocket onto the front output shaft.










7. Install the front drive sprocket retaining ring (3).










8. Install spring (2) and cups (1) on shift rail.










9. Insert magnet (1) in front case pocket (2).

OIL PUMP AND REAR CASE










CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft inner bearing race and will become mis-aligned if the bolts are loosened. If the transfer case failure has generated any debris which may have become trapped in the oil pump. the rear case and oil pump assembly MUST be replaced.

Lubricate the oil pump components before installation. Prime the oil pickup tube by pouring a little oil into the tube before installation.

1. Install new o-ring in pickup tube inlet of oil pump.
2. Position oil pickup tube and filter in rear case. Be sure pickup filter is seated in case pocket and that pickup tube is aligned in case notches. Be sure hose that connects tube to filter is securely positioned.
3. Install the transfer case position sensor (1). Tighten the sensor to 20-34 Nm (16-25 ft.lbs.).










4. Install the shift sector support (2). Tighten the sector support to 27-42 Nm (20-30 ft.lbs.).










5. Install detente plunger (3) and spring (2) into the front case half.
6. Install new o-ring on detente plug (1) and install plug in front case. Tighten plug to 16-25 Nm (12-18 ft. lbs.).










7. Install shift lever (1) onto the shift sector (3).










8. Install the shift lever bolt (2). Tighten the bolt to 20-34 Nm (15-25 ft.lbs.)










9. Shift the transfer case into a 4WD range. This will raise the mainshaft slightly and make installation of the rear case half much easier.
10. Verify that the transfer case alignment dowels are properly installed.
11. Apply bead of MOPAR(R) Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into case interior.
12. Align oil pump with mainshaft and align shift rail with bore in rear case. Then install rear case (1) and oil pump assembly. Be sure oil pickup tube remains in position during case installation.










CAUTION: Verify that shift rail, and case alignment dowels (3) are seated before installing any bolts. Case could be cracked if shaft rail or dowels are misaligned.

13. Install 4-5 rear case-to front case bolts to hold rear case in position. Tighten bolts snug but not to specified torque at this time.










14. Apply Loctite(TM) 242 to remainder of rear case-to-front case bolt threads and install bolts (3). Tighten all bolts to 20-27 Nm (15-20 ft. lbs.).

YOKE










1. Install yoke seal (2) onto front shaft (1).










2. Install yoke (2) onto front shaft. Then install and tighten a new yoke nut to 122-176 Nm (90-130 ft. lbs.) torque. Never re-use a yoke nut.

REAR EXTENSION

1. Clean mating surfaces of transfer case housing and the rear retainer of any original gasket material.
2. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of rear case. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into case interior.
3. Align and install rear extension on rear case.
4. Apply MOPAR(R) Silicone Sealer to threads of rear extension bolts. Then install extension bolts. Tighten the extension bolts to 16-25 Nm (12-18 ft.lbs.).
5. Install new seal in rear extension housing with Seal Installer 9041 and Universal Handle C-4171.









6. Install the rear companion flange (3) onto the output shaft.
7. Install bolts (4) into two threaded holes in the rear propeller shaft companion flange 180° apart.
8. Place the Holder 6719A (2) over the two bolts and use the Holder to install a new rear companion flange nut. Never re-use the companion flange nut once it has been installed. Tighten the companion flange nut to 122-176 Nm (90-130 ft.lbs.).