Part 3

ASSEMBLY - Continued

46. Install the upper thrust bearing.





47. Install the upper bearing race.





48. Install the thrust collar.





49. Install the clutch shim.





50. Install clutch upper snap ring.

NOTE: The clutch cam has the word "FRONT" stamped into. This identifies the orientation of the clutch cam to the front of the transfer case. Before installing the clutch cam, note the orientation of the clutch cam inner splines to the outer splines on the shift shaft. Install it such that the roller falls into low point of clutch cam.





51. Install the clutch cam.

NOTE: Before installing the worm drive gear, note the orientation of the worm drive gear inner splines to the outer splines on the shift shaft.





52. Install the worm drive gear.





53. Install the magnet into the magnet pocket.










54. Install a new o-ring (2) onto the oil pump tube (1).





55. Lubricate the oil tube o-ring with MOPAR(R) ATF+4 and install the tube into the oil pump.
56. Install the oil pump assembly.






NOTE: Do not use excessive amount of sealer as excess could be displaced into the oil pump. Keep sealer bead width to maximum of 3 mm (1/8 inch).

57. Apply bead of Mopar(R) Gasket Maker, or equivalent, to one of the mating surfaces of the front or rear housing.
58. Install the rear housing onto the front housing. Install the housing bolts. Tighten housing bolts in a crisscross pattern to 27 Nm (20 ft.lbs.).

CAUTION: Carefully align and thread (rotate counterclockwise) the worm shaft to install it into the transfer case. Failure to follow this caution may result in parts damage.





59. Install the worm shaft into the transfer case.

NOTE: It may be necessary to apply slight inward pressure on the worm shaft to seat the snap ring.





60. Install the worm shaft snap ring.





61. Using a suitable installer, install the shift motor seal.





62. Install a new o-ring onto the shift motor.






NOTE: Note the orientation of the shift motor shaft to the worm gear shaft.

63. Install the shift motor onto the transfer case. Install the shift motor bolts. Tighten the shift motor bolts to 13 Nm (9 ft. lbs.).






NOTE: It may be necessary to pull out on the shift shaft to properly seat the shift shaft snap ring.

64. Install the shift shaft snap ring.





65. Using a suitable installer, install the shift shaft seal.





66. Install a new o-ring onto the encoder.

NOTE: Before installing the encoder onto the transfer case, be certain to align the encoder shaft to the shift shaft and the dowel on the encoder to the hole in the case accordingly.





67. Install the encoder onto the rear transfer case housing. Install the encoder screws. Tighten the screws to 5-8 Nm (44-71 in.lbs.).










68. Using a suitable pry tool or a screw mounted in a slide hammer, remove the rear cover seal.
69. Using Installer (2) and Handle (1), install the rear cover seal.






NOTE: Do not use excessive amount of sealer as excess could be displaced into the oil pump. Keep sealer bead width to maximum of 3 mm (1/8 inch).

70. Apply bead of Mopar(R) Gasket Maker, or equivalent, to one of mating surfaces of the rear cover or rear housing. Align the tabs on the rear cover to the tabs on the rear housing and install the rear cover. Install the rear cover bolts. Tighten the rear cover bolts in a crisscross pattern to 27 Nm (20 ft.lbs.).





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





72. Install the companion flange onto the mainshaft.










73. Using Holder (1), install the rear output flange (2) nut. Tighten the nut to 122-176 Nm (90-130 ft.lbs.).