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Shift Forks, Sector, And MAINSHAFT

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the shift sector shaft bearing using a suitable socket until the bearing is flush to the bottom, inner edge of the bore. See Fig 1.
    Fig 1: Remove/Install Shift Sector Shaft Bearing
    GC0025419Courtesy of DAIMLERCHRYSLER CORP.
    1 - TRANSFER CASE
    2 - SOCKET
  2. Install a new shift sector shaft seal using a suitable socket until the seal is flush to the bottom of the bore lead-in chamfer.
  3. Install shift sector.
  4. Install new pads on low range fork, if necessary.
  5. Assemble low range fork and sleeve.
  6. Position low range fork and sleeve in case. Be sure low range fork pin is engaged in shift sector slot. See Fig 2.
    Fig 2: Install Range Fork And Sleeve Assembly
    GC0025429Courtesy of DAIMLERCHRYSLER CORP.
    1 - RANGE SLEEVE
    2 - RANGE FORK
  7. Install first mainshaft bearing spacer on mainshaft. See Fig 3.
  8. Install bearing rollers on mainshaft. See Fig 3. Coat bearing rollers with generous quantity of petroleum jelly to hold them in place.
  9. Install remaining bearing spacer on mainshaft. See Fig 3. Do not displace any bearings while installing spacer.
    Fig 3: Installing Mainshaft Bearing Rollers and Spacers
    GC0017452Courtesy of DAIMLERCHRYSLER CORP.
    1 - MAINSHAFT BEARING ROLLERS
    2 - BEARING SPACERS
  10. Install differential. See Fig 4. Do not displace mainshaft bearings when installing differential.
  11. Install differential snap-ring. See Fig 5.
  12. Install intermediate clutch shaft. See Fig 6.
    Fig 4: Differential Installation
    GC0017453Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL
    2 - MAINSHAFT
    Fig 5: Identifying Differential Snap-Ring
    GC0017429Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL SNAP-RING
    Fig 6: Identifying Intermediate Clutch Shaft
    GC0017428Courtesy of DAIMLERCHRYSLER CORP.
    1 - INTERMEDIATE CLUTCH SHAFT
  13. Install clutch shaft thrust washer. See Fig 7.
  14. Install clutch shaft snap-ring. See Fig 8.
  15. Inspect mode fork assembly. See Fig 9. Replace pads and bushing if necessary. Replace fork tube if bushings inside tube are worn or damaged. Also check springs and slider bracket. See Fig 9. Replace worn, damaged components.
    Fig 7: Identifying Clutch Shaft Thrust Ring
    GC0017427Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH SHAFT THRUST RING
    Fig 8: Identifying Intermediate Clutch Shaft Snap-Ring
    GC0017426Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
    2 - INTERMEDIATE CLUTCH SHAFT
    Fig 9: Mode Fork Assembly Inspection
    GC0017457Courtesy of DAIMLERCHRYSLER CORP.
    1 - SLIDER
    2 - MODE FORK
    3 - BUSHING/SPRING
    4 - TUBE
    5 - PADS
  16. Install mode sleeve in mode fork. See Fig 10. Then install assembled sleeve and fork on mainshaft. Be sure mode sleeve splines are engaged in differential splines.
  17. Install mode fork and mainshaft assembly in case. See Fig 11. Rotate mainshaft slightly to engage shaft with low range gears.
    Fig 10: Identifying Mode Fork And Sleeve
    GC0017425Courtesy of DAIMLERCHRYSLER CORP.
    1 - MAINSHAFT
    2 - MODE SLEEVE
    3 - MODE FORK ASSEMBLY
    Fig 11: Identifying Mainshaft And Mode Fork
    GC0017424Courtesy of DAIMLERCHRYSLER CORP.
    1 - MAINSHAFT ASSEMBLY
    2 - MODE FORK
  18. Rotate mode fork pin into shift sector slot.
  19. Install shift rail. See Fig 12. Be sure rail is seated in both shift forks.
  20. Rotate shift sector to align lock pin hole in low range fork with access hole in case.
  21. Insert an easy-out in range fork lock pin to hold it securely for installation. See Fig 13. Lock pin is slightly tapered on one end. Insert tapered end into fork and rail.
  22. Insert lock pin through access hole and into shift fork. See Fig 13. Then remove easy-out and seat the pin with pin punch.
    Fig 12: Identifying Shift Rail
    GC0017423Courtesy of DAIMLERCHRYSLER CORP.
    1 - SHIFT RAIL
    2 - MODE FORK
    Fig 13: Installing Low Range Fork Lock Pin
    GC0017454Courtesy of DAIMLERCHRYSLER CORP.
    1 - LOW RANGE FORK LOCK PIN
    2 - ACCESS HOLE
    3 - EASY-OUT
  23. Install plug in lock pin access hole.
  24. Install detent plunger, detent spring and detent plug in case. See Fig 14.
Fig 14: Identifying Detent Plunger, Spring And Plug
GC0017363Courtesy of DAIMLERCHRYSLER CORP.
1 - PLUNGER
2 - O-RING
3 - PLUG
4 - SPRING
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