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Transfer Case Reassembly

NOTE: When installing bearings, ensure bearing bores are aligned with oil feed holes.
  1. Lubricate all internal parts with Dexron II ATF or equivalent. Install needle bearing into drive sprocket and rear case. Ensure drive sprocket bearing is flush on synchronizer side. Install input gear bearing. See Figure .
  2. Install bearing in front case and oil pump. Install mainshaft pilot bearing in input shaft. Install thrust washer and carrier lock ring on input gear. Install input gear bearing and snap ring. Install input gear, bearing and planetary assembly in annulus gear. Install input gear lock ring.
  3. Install extension housing oil seal. Install front case oil seal. Apply bead of silicone sealer to input shaft bearing retainer mating surface. Install input shaft bearing retainer and oil seal. Apply Loctite to bearing retainer bolt threads before installing. Tighten to specification. See TORQUE SPECIFICATIONS  . Install range shift hub, mode fork, range selector and range fork. Install shift lever, washer and nut.
  4. Install synchronizer insert springs on synchronizer hub. Install synchronizer inserts on synchronizer hub and slide synchronizer sleeve over assembly. Install synchronizer stop ring on synchronizer sleeve.
  5. Install drive sprocket on mainshaft. Install synchronizer assembly on mainshaft. Install sector with shaft, range shift lever, washer and nut. Tighten to specification. Install range fork and range shift hub.
  6. Install front output shaft. Install mainshaft, drive chain and driven sprocket as a unit in front case. Install driven sprocket snap ring. Install mode shift fork and pin on shift rail. Install mode shift fork assembly through range shift fork onto synchronizer sleeve. Install mode fork spring.
  7. Install oil pick-up tube, screen and magnetic washer to rear case. Apply silicone sealant to oil pump housing mating surface. Install oil pump with new "O" ring. Apply bead of silicone sealer to case mating surfaces. Install rear case on front case. Install bolts and tighten to specification. See TORQUE SPECIFICATIONS  . Install snap ring, speedometer gear and snap ring onto mainshaft.
  8. Install rear bearing retainer housing. Apply Loctite to rear bearing retainer bolt threads before installing. Install snap ring on mainshaft above rear bearing. Apply silicone sealant to extension housing mating surface. Install extension housing. Apply Loctite to extension housing bolt threads before installing and tighten bolts to specification.
  9. Install range selector plunger, spring and poppet screw. Install speedometer sensor. Install indicator switch. Install front companion flange, washer and nut. Tighten nut to specification.
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