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Shift Forks 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.
Fig 1: Removing/Installing Mode Hub
GC0005856Courtesy of DAIMLERCHRYSLER CORP.
1 - OUTPUT SHAFT
2 - MODE HUB
  1. Lubricate mainshaft splines with recommended transmission fluid.
  2. Install the mode hub (1) onto the output shaft. See Fig 1.
    Fig 2: Removing/Installing Mode Hub Retaining Ring
    GC0005857Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - RETAINING RING
    3 - MODE HUB
  3. Install the mode hub retaining ring (2) onto the output shaft (1). See Fig 2.
    Fig 3: Removing/Installing Sprocket Hub
    GC0005858Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - SPROCKET HUB
  4. Install the sprocket hub (2) onto the output shaft (1). See Fig 3.
    Fig 4: Removing/Installing Clutch Gear
    GC0005859Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - CLUTCH GEAR
    3 - MODE HUB
  5. Install the clutch gear (2) onto the output shaft (1). See Fig 4.
    Fig 5: Removing/Installing Drive Sprocket
    GC0005860Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - DRIVE SPROCKET
  6. Install the drive sprocket (2) onto the output shaft (1). See Fig 5.
    Fig 6: Removing/Installing Drive Sprocket Thrust Washer
    GC0005861Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - THRUST WASHER
    3 - DRIVE SPROCKET
  7. Install the drive sprocket (3) thrust washer (2) onto the output shaft (1). See Fig 6.
    Fig 7: Removing/Installing Drive Sprocket Retaining Ring
    GC0005862Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - RETAINING RING
    3 - DRIVE SPROCKET
  8. Install the drive sprocket retaining ring (2) onto the output shaft (1). See Fig 7.
    Fig 8: Removing/Installing Shift Sector
    GC0005863Courtesy of DAIMLERCHRYSLER CORP.
    1 - SHIFT SECTOR
  9. Lubricate sector shaft with transmission fluid and install shift sector (1) in case. Position slot in sector so it will be aligned with shift fork pin when shift forks are installed. See Fig 8.
    Fig 9: Removing/Installing Sector Support
    GC0005864Courtesy of DAIMLERCHRYSLER CORP.
    1 - SECTOR SUPPORT
    2 - FRONT CASE
    3 - SECTOR SHAFT
  10. Install the shift sector support (1). See Fig 9. Tighten the sector support to 27-42 N.m (20-30 ft.lbs.).
    Fig 10: Install Range Fork And Hub Assembly
    GC0005884Courtesy of DAIMLERCHRYSLER CORP.
    1 - RANGE HUB
    2 - RANGE FORK
  11. Assemble and install range fork (2) and hub (1). See Fig 10. Be sure hub is properly seated in low range gear and engaged to the input gear.
  12. Align and insert range fork pin in shift sector slot.
  13. Install the range fork retaining ring.
    Fig 11: Removing/Installing Mode Fork and Shift Rail
    GC0005837Courtesy of DAIMLERCHRYSLER CORP.
    1 - MODE FORK
    2 - SHIFT RAIL
    3 - MODE SLEEVE
  14. Install mode fork (1) and shift rail (2) onto the mode sleeve (3). See Fig 11.
  15. Install the mode fork, sleeve, and shift rail into the transfer case.
    Fig 12: Removing/Installing Mainshaft
    GC0005838Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT CASE
    2 - MAINSHAFT
  16. Install mainshaft (2) into the transfer case (1). See Fig 12. Guide mainshaft through the mode and range sleeves and into the input gear.
    Fig 13: O-Ring Installation On Detent Plug
    GC0005885Courtesy of DAIMLERCHRYSLER CORP.
    1 - O-RING
    2 - DETENT PLUG
  17. Install new o-ring on detent plug (2). See Fig 13.
    Fig 14: Removing/Installing Detent Plug, Spring and Plunger
    GC0005841Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT CASE
    2 - DETENT PLUG
    3 - DETENT SPRING
    4 - DETENT PLUNGER
  18. Install detent plunger (4), spring (3), and plug (2). See Fig 14. Tighten the plug to 16-25 N.m (12-18 ft. lbs.).
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