Part 2

ASSEMBLY (Continued)

28. Install the hub drive and clutch gear assembly (1) onto the mainshaft.




SYNCHRONIZER HUB





29. Install the synchronizer hub (1) onto the mainshaft.




SYNCHRONIZER HUB SNAP RING





30. Install the synchronizer hub snap ring (1) onto the mainshaft.




SHIFT FORK AND SYNCHRONIZER SLEEVE





31. Install the shift fork (1) and synchronizer sleeve (2) onto the shift rail and mainshaft.




MAGNET
32. Clean and install the magnet into the pocket.




OIL TUBE O-RING





33. Install a NEW o-ring seal (2) onto the oil tube (1).




OIL PUMP ASSEMBLY





34. Lubricate the oil tube o-ring with MOPAR(R) ATF+4 and install the tube into the oil pump.
35. Install the oil pump (2) onto the mainshaft while installing the oil pump pick-up into the pocket in the case.










36. Install the sector shaft (2) into the rear housing (1).










37. Install the retaining ring (2) onto the shift sector shaft (1).










38. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3 mm (0.125 inch). Do not use excessive amount of sealer as excess will be displaced into case interior and potentially clog the oil pump screen.
39. Install the rear housing (1) into the front housing (2).

NOTE: Use an alignment dowel (2) in the combination of the front (1) and the rear housing (3).




ALIGNMENT DOWEL














40. Install the bolts (2) to hold the rear housing (1) to the front housing (3). Tighten the bolts at the dowel locations first, then the remainder of the bolts in a criss-cross pattern. Tighten the bolts to 27 Nm (20 ft.lbs.).










41. Install the anti-rotation bracket (1) onto the shift rail (2).










42. Install the sector roller (1) onto the shift rail (2).
43. Using a suitable punch, align the holes in the sector roller with the hole in the shift rail and install the roll-pin to secure the sector roller to the shift rail.




DETENT ASSEMBLY





44. Install the detent assembly (1) into the rear case (2). Tighten the bolt to 20 Nm (15 ft. lbs.).










45. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of rear housing as shown (2). Keep sealer bead width to maximum of 3 mm (1/8 inch). Do not use excessive amount of sealer as excess will be displaced into case interior and potentially clog the oil pump screen.










46. Install the rear cover (1) onto the rear housing (2).




REAR RETAINER





47. Install the bolts (3) holding the rear cover (2) onto the rear housing (1). Tighten the bolts at the dowel locations first, then the remainder of the bolts in a criss-cross pattern. Tighten the bolts to 27 Nm (20 ft.lbs.).




SHIFT MOTOR SEAL RING





48. Install the seal ring (1) onto the shift motor (2).






NOTE: Verify that the missing tooth (2) in the shift motor drive spline (1).







NOTE: .and the transfer case drive spline (1) missing tooth (2) are aligned. It may be necessary to manually shift the transfer case if the shift motor and transfer case shaft are not aligned.











49. Install the shift motor and mode sensor assembly (1) onto the shift sector (2) and the transfer case (3).










50. Install the bolts (1) to hold the shift motor and mode sensor assembly (2) to the transfer case. Tighten the bolts to 27 Nm (20 ft.lbs.).




DAMPER





51. Install the damper (1), (if equipped), and bolts (2) onto the case. Tighten the bolts to 27 Nm (20 ft. lbs.).




OUTPUT FLANGE O-RING





52. Install the o-ring into the rear output flange.




REAR OUTPUT FLANGE NUT





53. Install the rear output flange onto the main shaft.
54. Using Holder (1), install the rear output flange (2) nut. Tighten the bolts to 122-176 Nm (90-130 ft.lbs.).