Reassembly

REASSEMBLY

CASE ASSEMBLY
1. If ring gear was removed for replacement, align serrations on OD of new ring gear with those in transfer case. Press in ring gear, chamfered end first. Make sure gear is not cocked and is firmly seated in case.
2. If removed, press two new dowel pins into case.
3. Press in ball bearing to bottom in transfer case and install retaining ring.
4. Position new oil seal and press in to seat seal flange against transfer case.









SHIFT CAM (ELECTRIC PARTS)
1. Insert spacer in torsion spring and install over free end of shift shaft.




2. Slide torsion spring and spacer on shift shaft up to drive tang and position first spring end to left (Viewed from free end of shaft) of drive tang.




3. Twist second spring end to right of drive tang on shift shaft.




4. Push torsion spring and spacer together back as far as they will go.
5. Slide electric shift cam onto shift shaft, drive tang on cam first.
Position drive tang on cam so that it will go under drive tang on shift shaft and between spring ends and slide cam as far as it will go.





ADAPTER, INPUT SHAFT AND CARRIER
1. Lay planet carrier assembly on work bench with end having groove for retaining ring up.
2. Install sun gear with hub end up. Rotate gear of planet carrier assembly as required until sun gear is fully meshed.
3. Align tabs and install thrust plate into planet carrier assembly.
4. Install retaining ring (16) to complete gear carrier assembly.




5. If removed, position needle bearing and press into input shaft to dimension shown. Press in new sleeve bearing to complete input shaft assembly.
6. Lift up gear carrier assembly and install input shaft assembly up through gear carrier assembly. Install thrust washer and press bearing over end of input shaft assembly. Retain bearing on input shaft with retaining ring in shaft groove.
7. If removed, press new pin into front adapter.
8. Position oil seal and press into front adapter to dimension shown.
9. Install snap ring in groove in front adapter with long ends of snap ring in adapter groove to complete front adapter assembly.
10. Position front adapter assembly with face that mates with transfer case up. Support on wood blocks to provide clearance for input shaft assembly. Position assembled input shaft and carrier group over front adapter with input shaft down. Lower shaft and carrier group while expanding long ends of snap ring until snap ring engages groove in outside diameter of bearing.




11. Apply continuous 1/16 in.(1.6 mm) bead of sealant (Neutral Cure RTV, Loctite 598) all around transfer case mounting face for front, adapter. Center sealant bead between edges of face. Circle bolt holes.
12. Install assembled adapter, input shaft and carrier group on transfer case and attach with six bolts. Torque bolts to 20 - 34 lb-ft (27 -46 Nm)
13. Install breather bard and torque to 6 - 14 lb-ft (8 - 19 Nm).

FRONT OUTPUT SHAFT
1. If removed, press deflector onto yoke.
2. Position output shaft in transfer case and install yoke assembly, oil seal, washer and nut.
3. Hold yoke and torque nut to 150 - 180 lb-ft (203 - 244 Nm).





REDUCTION SHIFT
1. If disassembled for parts replacement, assemble reduction shift fork assembly using new pin, roller and retainer assembly.
Press pin, roller and retainer assembly in to bore in reduction shift fork until retainer passes completely through and snaps in place. Make sure that cam roller turns freely.
2. Install two fork facings on reduction shift fork assembly.
3. Engage reduction shift fork assembly with reduction hub and position in transfer case, reduction hub in gear carrier assembly previously installed.
4. Install output shaft, engaging output shaft end with input shaft bearings and output shaft spline with reduction hub.





CHAIN DRIVE
1. On work bench, next to transfer case assembly, position driven sprocket (with internal spline) at front output shaft end of case and drive sprocket(with smooth bore) at output shaft end.
2. Assemble drive chain around sprockets.
3. Grasp each sprocket, hold drive chain tight and parallel with transfer case, and install chain drive assembly over output shaft. It may be necessary to rotate driven sprocket slightly to engage splines on front output shaft.
4. Install spacer on front output shaft. Install snap ring in shaft groove over spacer.





LOCKUP SHIFT
1. Assemble return spring and lockup hub in lockup collar and retain with snap ring, completing 2W-4W lockup assembly.
2. Install rail shaft in transfer case, through reduction shift fork assembly previously installed and into blind hole in case.
3. Engage lockup fork in groove in 2W-4W lockup assembly and slide this group down over output shaft and rail shaft.
4. Install shift collar hub, engaging splines on output shaft and in 2W-4W lockup assembly.
5. On electric shift units only, install electric shift cam group previously assembled and clutch housing as follow :
(1) Position electric shift cam group rotated so that end of torsion spring will contact side of reduction shift fork assembly that faces up, toward top of case.
(2) Holding rail shaft down, raise up fork assemblies slightly. Rotate electric shift cam group into position so that roller on reduction shift fork assembly is in groove in shift cam and button on lockup fork is on cam end. Then lower this group of parts into the transfer case engaging shift shaft on pin in transfer case.
(3) Position clutch housing in transfer case over shift collar hub. Attach with retaining ring in clutch collar hub groove.









CASE COVER




1. Position cover on bed of suitable press so that open face of cover is up and parallel with press bed.
2. Position end of needle bearing with identification marking up and press into cover until upper end of bearing is 1.593 -1.603 in. (40.47 -40.97 mm) below face of cover that mates with transfer case.
3. Press in ball bearing to bottom in cover and install snap ring.
4. On electric shift units only, install parts as follow :
(1) Verify that four O-rings (one on wire and one each on three studs) are in place on clutch coil assembly. Install clutch coil assembly in inside of cover, with electrical wire and studs extending through cover, with electrical wire and studs extending through cover. Use care not to kink or trap electrical wire under clutch coil assembly. Attach with three nut sand torque to 6 -8 lb-ft (8 - 11 Nm).
(2) Install motor bearing and oil seal in cover.




5. Install return spring over rail shaft in transfer case to rest on shift fork.
6. Install magnet in slot in transfer case.
7. Apply continuous 1/16 in. (1.6 mm) bead of sealant (Neutral Cure RTV, Loctite 598) all around transfer case mounting face for cover assembly. Center sealant bead between edges of face. Circle bolt holes. Remove excess if sealant bead is larger than 1/16 in. (1.6 mm).




8. Install cover assembly on transfer case. All of the following alignment conditions must be met for the cover assembly to seat on transfer case properly.
(1) Cover holes with transfer case dowel pins.
(2) Cover bearings with output shafts.
(3) Blind hole in cover with rail shaft. Make sure spring in not cocked. On electric shift, check with pen light through cover hole for speed sensor.
(4) On electric shift units, cover bearing with shift shaft.
9. Install nine bolts positioning identification tag and wiring clip under bolt heads at locations. Torque bolts to 20 - 34 lb-ft (27 -46 Nm).
10. Install speedo gear over spline of output shaft into cover assembly.
11. Press new oil seal into cover assembly.





EXTERNAL ELECTRIC SHIFT
1. Position motor assembly so that triangular slot in motor will align with shift shaft. Move motor in to engage shift shaft and contact cover. Then rotate motor in clockwise direction until motor is in correct position and mounting holes are aligned.
2. Fit O-ring on speed sensor and install speed sensor assembly in cover. Install bracket so that it is over speed sensor and install three bolts. Torque bolts to 6 - 8 lb-ft (8 - 11 Nm).
3. Install bolt and washer at bracket end of motor assembly and torque to 6 - 8 lb-ft (8 - 11 Nm).










REASSEMBLY

1. Before assembly, lubricate all parts with the specified grease oil.
2. If removed, drive the bearing into the front output case bore.
3. Install the internal snap ring that retains the bearing to the front case.
4. If removed, install the front yoke to flange seal in the front case bore.
5. If removed, install the yoke to flange seal into the mounting adapter bore.




6. If the input shaft needle bearing and bushing were removed, install a new bearing and bushing.
7. The recessed face of the sun gear and the snap ring groove on the bearing outer race should be toward the rear of the transfer case.
8. The stepped face of the thrust washer should face toward the bearing.
9. Slide the sun gear, thrust plate and thrust washer into position on the input shaft.
10. Press the bearing over the input shaft.
11. Install the external snap ring to the input shaft.
12. Install the front planet to the sun gear and input shaft.
13. Install the internal snap ring to the planetary carrier.




14. Place the tanged snap ring in the case.
Expand the snap ring with the snap ring pliers and install the planetary carrier assembly.
Check the installation by holding the case and carefully tapping the face of the input shaft against a wooden block to make sure the snap ring is installed.
15. Remove all traces of gasket sealant from the front case and mounting adapter mating surfaces.




16. Install the high-low shift fork and high-low collar as an assembly into the front planet.




17. Check the pump to make sure the pump rotates freely.
18. Inspect the outside surfaces and bore of the oil pump.




19. Install the output shaft and oil pump in the input shaft. Make sure that the internal splines of the output shaft engage the internal splines of the high-low shift collar. Make sure that the oil pump retainer arm and oil filter leg are in the groove and slot of the front case.




20. Install the oil pan magnet in the slot in the front case just above the oil filter leg.
21. Install the front output shaft in the front case.




22. Install the thrust washer on the rear output shaft.
23. Install the chain, drive sprocket and driven sprocket as an assembly over the output shaft.

CAUTION:
The driven sprocket (on the front output shaft) must be installed with the marking REAR facing toward the rear case, if so marked.




24. Install tone wheel onto the front output shaft. Make sure the spline on the tone wheel engages the spline on the front output shaft.
25. Install clutch pack assembly onto the rear output shaft. Make sure that the spline on the clutch pack engages to the spline of the sprocket.




26. Install snap ring onto the rear output shaft. Start the snap ring over the spline and use the wave spring to seat the snap ring in the snap ring groove.
If the snap ring will not install, the thrust washer inside the clutch pack may not be seated properly.




27. Three slots on the thrust washer must be aligned with the three tabs on the clutch pack housing.
28. Install the apply cam onto the rear output shaft.
29. Install three balls into the apply cam.
30. Install cam and coil housing assembly onto rear output shaft.
31. Install thrust bearing assembly onto output shaft.




32. Install the clutch coil from inside the rear case until the wire and studs extend through the cover.
33. Install the washers and nuts and tighten to 8 - 11Nm.




34. Slide the spring spacer on the cam shaft and position it beneath the drive tang.
35. Place the torsion spring on the cam shaft. Position the first spring tang to the left of the cam shaft drive tang.




36. Wind the second spring tang clockwise past the drive tang.




37. Push the torsion spring and sleeve in as far as it will go.
38. Install the helical cam and slide the drive tang between the torsion spring tangs as far as it will go.




39. Install the pin on the tang end of the helical cam into the hole in the front case.
Position the torsion spring tangs so that they are pointing toward the top side of the transfer case and just touching the high-low shift fork.

CAUTION:
Do not bend the helical cam during installation to the front case be cause of possible damage to the pin at the tang end of the motor shaft.

40. Install the shift rail through the high-low shift fork and make sure that the reverse gear shift rail is seated in the front case bore.
41. Install upper and lower speed sensors into the cover. Feed the coil wire through the upper speed sensor wire shield.




42. Install upper tone wheel, speedometer gear and rear output seal.




43. Coat the mating surface of the front case with sealant.
44. The following procedure must be followed prior to installing the rear case onto the front case half :
(1) Align the output shaft with the rear case output shaft bore.
(2) Align the helical cam with the rear case motor bore. If difficulty is encountered with seating the rear case, tap the rear output shaft with a sharp blow using a rubber mallet in a direction away form the triangular shaft while pushing down on the rear case.
45. Install the bolts retaining the case halves and tighten to 25 - 37 Nm (250 - 370 kg-cm, 19 25 lb-ft).




46. Install shift shaft oil seal if it is not installed.




47. Using pliers equipped with soft jaws, rotate the triangular shaft so it is aligned with the triangular slot in the transfer case shift motor. If triangular shaft will not rotate, rotate the rear output shaft.
48. Slightly loosen the two nuts that attach the slotted support bracket to the end of the motor house.
49. Apply the sealant to motor housing base and install on transfer case.
50. Install the transfer case shift motor.
51. Holding the slotted support bracket tight against the motor housing end secure the bracket to the transfer case, tightening the bolt with lockwasher to 8 - 11 Nm (80 - 110 kg-cm, 6 - 8 lb-ft).
52. Retighten the two nuts that attach the slotted support bracket to the end of the motor to 3-4 Nm (30 - 40 kg-m, 2 - 3 lb-ft).