Standard Procedure

WARNING: This page is about a different variant/trim than selected.

If installing a new clutch pack, check the clutch pack clearance, and select a new spacer if necessary. See Transmission and Transfer Case/Transfer Case - Adjustments .

Fig 1: Clutch Assembly And Input Shaft
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Install the Clutch Assembly (1) onto the input Shaft (2).

Fig 2: Snap Ring And Input Shaft
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Install the Snap Ring (1) onto the Input Shaft (2).

Fig 3: Input Shaft Wave Spring
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Install the wave spring (1) onto the input shaft.

Fig 4: Ball Bearings And Apply Cam
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Install the apply cam (2), and the ball bearings (1).

Fig 5: Clutch Rotor
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Install the clutch rotor (1) onto the input shaft.

Fig 6: Input Shaft Bearing
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Install the bearing (1) onto the input shaft.

Fig 7: Spacer
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Install the spacer (1).
Apply a bead of Loctite® 598 HB to the front case half sealing surface.

Fig 8: Transfer Case Rear Cover
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Install the rear cover (1). Tighten the case bolts to 31 Nm (23 ft. lbs).

Fig 9: Rear Output Flange
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Install the rear output flange (1).

Fig 10: Outer Rear Output Shaft Seal
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Install a new outer rear output shaft seal (1).

Fig 11: Rear Output Flange Washer
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Install the rear output flange washer (1).
Install the rear output flange nut.

Fig 12: Holder 6958 And Rear Output Flange
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Install Holder 6958 (1) onto the rear output flange (2). Tighten the rear output flange nut to 319 Nm (235 ft. lbs.).