ASSEMBLY
BEARINGS AND SEALS
1.
Position the input gear bearing in the input retainer bearing bore. Spread the snap-ring captured in the retainer with suitable snap-ring pliers and press the bearing into place. Verify that the
snap-ring has engaged the groove in the bearing.
2.
Start front output shaft bearing (3) in case. Then seat bearing with Universal Handle C-4171 (1) and Bearing Installer 6953 (2).
3.
Install the front output shaft bearing retaining ring.
4.
Install the rear output shaft bearing into the rear case half with Bearing Installer 6953 (3) and Universal Handle C-4171 (2).
5.
Remove the input gear pilot bearing using Remover Jaws 8240 and Cup 8148.
6.
Remove the input gear cup plug with a suitable drift (1)and hammer inserted from the front of the input gear (2).
7.
Install a new input gear cup plug with Cup Seal Installer 9045 and Universal Handle C-4171.
8.
Install new input gear pilot bearing with Bearing Installer 9047 and Universal Handle C-4171.
9.
Remove the front output shaft rear bearing with the screw and jaws from Remover L-4454 (2) and Cup 8148 (3).
10.
Install new bearing with Universal Handle C-4171 (1) and Bushing Installer 5066 (3).
11.
The bearing (1) bore is chamfered at the top. Install the bearing so it is flush with the lower edge of this chamfer (2).
INPUT AND PLANETARY GEAR
1.
Install the annulus gear (2) into the front case half (1).
2.
Align and install low range planetary (2) assembly into the front case half (1). Be sure low range planetary pinions are engaged in annulus
gear (3).
3.
Install the low range planetary plastic spacer (2) onto the low range planetary carrier (1).
4.
Clean gasket sealer residue from retainer and inspect retainer for cracks or other damage.
5.
Apply a 3 mm (1/8 in.) bead of MOPAR Gasket Maker, or equivalent silicone adhesive, to sealing surface of retainer.
6.
Install the front input retainer (1) onto the front case half (2).
7.
Install bolts (3) to hold retainer (1) to transfer case (4). Tighten to 21 Nm (16 ft. lbs.) of torque.
8.
Install the input gear (2) to the low range planetary assembly and the input gear bearing.
9.
Install the input gear retaining snap-ring (3) onto the input gear (2).
10.
Install new oil seal in front input retainer with Seal Installer 8841 (2) and Universal Handle C-4171 (1).
SHIFT FORKS AND MAINSHAFT
1.
Lubricate mainshaft splines with recommended transmission fluid.
2.
Install the drive sprocket drive hub (2) onto the mainshaft (1). Verify that the long shoulder is towards the front of the mainshaft.
3.
Install the mode hub (2) onto the mainshaft (1).
4.
Install the mode hub snap-ring (3) onto the mainshaft (1).
5.
Rotate the mainshaft (1) 180 degrees and install the sliding clutch gear (2) onto the drive sprocket drive hub.
6.
Install the mainshaft drive sprocket (2) onto the drive hub.
7.
Install the mainshaft drive sprocket retaining ring (3) onto the drive hub.
8.
Support front case on wood blocks so case interior is facing up. Place blocks between mounting studs on forward surface of case.
9.
Lubricate mainshaft components with transmission fluid.
10.
Lubricate sector shaft with transmission fluid and install shift sector (2) in case (1). Position slot in sector so it will be aligned with
shift fork pin when shift forks are installed.
11.
Assemble and install range fork (1) and hub (2). Be sure hub is properly seated in low range gear and engaged to the input gear.
12.
Align and insert range fork pin in shift sector slot.
13.
Install mode fork (1) and mode sleeve (2). Verify that the long side of the mode sleeve is towards the front of the transfer case.
14.
Install the shift rail (2) through the shift forks and into the shift rail pocket in the front case half (1).
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 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™ 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 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 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 degrees apart.
8.
Place the Holder 6719 (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.).