Assembly

1. If removed, install a new front output shaft rear needle bearing assembly in rear case half using a hammer and needle bearing installer tool No. T90T-7127-A and universal handle tool No. T80T-4000-W or equivalents.
2. If removed, install a new rear output shaft needle bearing assembly in rear case half using a hammer, needle bearing tool No. T90T-7127-A and universal hammer tool No. T80T-4000-W or equivalent, from the inside of the case.
3. If removed, install a new steel bushing for rear output shaft in the rear case half using a hammer with bushing replacer tool No. T80L-77034-A and T90T-7127-H or equivalent, from the outside of the case.
4. If removed, install oil baffle in inside of front case half. Apply threadlock and sealer No. EOAZ-19554-AA or equivalent to the threads of capscrews that fasten baffle to the case. Torque the capscrews to 25-35 inch lbs.
5. Lubricate all parts with automatic transmission fluid.
6. Install rear case half in holding fixture tool No. T57L-500-B or equivalent, then install rear output shaft assembly in rear case half. Ensure the bearing on the shaft is correctly installed in the bore of the rear case half.
7. Install snap ring that retains rear output shaft in case.
8. Install planetary ring gear in case, then the thrust washer in the bottom of the planetary ring gear.
9. Install chain and sprockets on the front output shaft assembly, then install the chain, shaft, clutch, and planetary gear assembly into rear case half as an assembly.
10. Install wires for the electric clutch assembly in the slot in rear case.
11. Install the roller bearing in the front case half.
12. Install a 1/8-1/4 inch bead of non-acid cure silicone rubber No. E7TZ-19562-A or equivalent on mating surface of rear case half. Front case must be installed on the rear case half within five minutes after the gasket material has been installed.
13. Install the front case half on the rear case half using guide pins to line up case halves, then install tags and clips on the transfer case.
14. Apply threadlock and sealer No. EOAZ-19554-AA or equivalent to threads of case capscrews, then install capscrews in the case halves by hand. Torque capscrews to 20-30 inch lbs. Do not use air tools to tighten the case half capscrews. If case halves are replaced, use new self-tapping screws.
15. Install front output shaft retaining snap ring in the case, then install O-ring on shoulder of end of the front output shaft.
16. Lubricate lips of front output shaft oil seal with automatic transmission fluid, then install seal using seal installer tool No. T90T-7127-D or equivalent.
17. Install steel bushing on the front output shaft with the inner diameter O-ring groove toward the O-ring.
18. Install deflector on front output shaft.
19. Apply threadlock and sealer to threads of new front input shaft locknut, then using front output shaft holding tool No. T90T-7127-F and front output shaft nut wrench T90T-7127-E or equivalent, torque nut to 115-165 ft. lbs.
20. Place alignment marks on blind spline of the front output shaft and oil deflector to ease installation of front drive shaft.
21. Lubricate lips of rear output shaft seal with automatic transmission fluid, then using seal installer tool No. T61L-7657-A or equivalent, install seal in nose of rear case half. Ensure the slot in tool is installed over tab on seal and the hole in the bottom of the seal is at the six o'clock position.
22. Lubricate lips of input shaft oil seal with automatic transmission fluid, then using seal installer tool No. T90T-7127-B, install oil seal in the front case half.
23. If removed, install vent hose on the front case half. Ensure vent hose opening is installed toward the rear case half.
24. Connect wiring harness to the clips on the transfer case, then connect sensor electrical connectors.
25. Connect socket for electric clutch assembly to the wiring harness.
26. Add necessary fluid.