Assembly

Transfer Case - 2-Speed Torque-On-Demand

























Assembly

1. Using the Valve Stem Oil Seal Installer, carefully install the shifter shaft seal.





2. Using the Differential Bearing Cup Installer with the Adapter, press the front output shaft support bearing into the case.





3. Using the Input Shaft Oil Seal Installer, install a new oil seal.





4. Using the Input Shaft Oil Seal Installer, install a new oil seal.





5. Install the front output shaft and flange and snap ring.





6. Using a suitable press and the Input Shaft Bearing Installer, install the bushing and the bearing, if removed.





7. Using a suitable press, install the planetary gear carrier support bearing, if removed.





8. Install a new snap ring.





9. Install the front planetary gear set assembly.

1. Expand the snap ring.

2. Position the front planetary gear set assembly and release the snap ring.





10. Install the shift rail.





11. Install the reduction shift fork and the high-low collar as an assembly.





12. Install the electric shift cam assembly.





13. Install the pump assembly and the rear output shaft as an assembly.





14. Install the thrust washer.





15. Install the oil pan magnet.





16. Install the drive chain and the 2 sprockets as an assembly.





17. NOTICE: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as it was located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem can occur.

Install the clutch pack assembly.





18. Install a new snap ring.





19. Install the wave spring.





20. Install the apply cam and 3 steel balls.

21. Install the cam and coil housing assembly.





22. Install the thrust bearing.





23. Using the Wheel Hub Bearing Cup Installer with the Adapter, install the front output shaft rear bearing into the case.





24. Install the driven sprocket thrust washer.





25. Using the Wheel Hub Bearing Cup Installer with the Adapter, install the rear output shaft rear bearing into the case.





26. Position and support the clutch coil assembly, then install the 3 nuts.
- Tighten to 10 Nm (89 lb-in).





27. NOTICE: Applying excess silicone rubber can damage the internal components.

Apply a 3 mm (0.11 in) bead of silicone rubber on the rear case mating surface.





28. Assemble the front and rear case halves.





29. Install the 17 transfer case bolts.
- Tighten the bolts evenly in a star pattern to 25 Nm (18 lb-ft).





30. Using the Input Shaft Oil Seal Installer, install a new yoke-to-flange oil seal.





31. Install a new output flange oil seal.

32. NOTE: Align the index marks made during disassembly.

Install the output flange.

33. Install the output shaft yoke washer.

34. Using the Drive Pinion Flange Holding Fixture to hold the output flange. Install the rear output shaft flange nut.
- Tighten to 355 Nm (262 lb-ft).





35. NOTE: Make sure the motor mounting surfaces are clean.

Apply a 3 mm (0.11 in) bead of sealant to the motor mounting surface on the case.





36. Position the transfer case shift motor and install the 4 bolts.
- Tighten to 10 Nm (89 lb-in).





37. Seat the coil wire pin into the electrical connector. Install the connector interlock.





38. Position the heat shield and install the 3 heat shield bolts.
- Tighten to 16 Nm (142 lb-in).





39. Install the transfer case in the vehicle. For additional information, refer to Transfer Case Transfer Case - Installation.

40. Fill the transfer case. For additional information, refer to Transfer Case Draining and Filling Procedures.