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Service Information: Assembly

Fig 1: Remove Input Gear Bearing
GC0027432Courtesy of DAIMLERCHRYSLER CORP.
1 - HANDLE C-4171
2 - INSTALLER 8693A
3 - FRONT HOUSING
  1. Remove the input shaft bearing from the front case (3) with Handle C-4171 (1) and Installer 8693A (2). See Fig 1.
    Fig 2: Install Input Gear Bearing
    GC0027433Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR BEARING
    2 - FRONT CASE
  2. Install the new input gear bearing into the front case (3) using Installer 8152 (2), inverted, and Handle C-4171 (1). See Fig 2.
    Fig 3: Remove Front Output Shaft Bearing
    GC0027431Courtesy of DAIMLERCHRYSLER CORP.
    1 - HANDLE C-4171
    2 - INSTALLER 7829A
    3 - FRONT HOUSING
  3. Using Installer 7829A (2) and Handle C-4171 (1), remove front output shaft bearing from the front case (3). See Fig 3.
    Fig 4: Install Front Output Shaft Bearing
    GC0027430Courtesy of DAIMLERCHRYSLER CORP.
    1 - HANDLE C-4171
    2 - INSTALLER 8152
    3 - FRONT HOUSING
  4. Start front output shaft bearing in the front case. Using Installer 8152 (2), inverted, and Handle C-4171 (1), seat the bearing in the front case (3). See Fig 4.
    Fig 5: Install Rear Output Shaft Bearing
    GC0027429Courtesy of DAIMLERCHRYSLER CORP.
    1 - HANDLE C-4171
    2 - INSTALLER 8152
    3 - REAR HOUSING
  5. Remove the main shaft rear bearing from the rear case using Installer 5066 and Handle C-4171.
  6. Install the new main shaft rear bearing into the rear case (3) using Installer 8152 (2), inverted, and Handle C-4171 (1). See Fig 5.
    Fig 6: Remove/Install Front Output Shaft and Flange
    GC0027421Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT HOUSING
    2 - FRONT OUTPUT SHAFT
  7. Install a new front output shaft seal with Installer 6560.
  8. Install the front output shaft assembly (2) into the front case (1) and the front output shaft front bearing. See Fig 6.
    Fig 7: Remove/Install Front Output Shaft Retaining Ring
    GC0027420Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  9. Install the retaining ring (2) onto the front output shaft (1). See Fig 7.
    Fig 8: Remove/Install Input Gear
    GC0027419Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT HOUSING
    2 - INPUT GEAR
  10. Install the input gear (2) into the front case (1). See Fig 8.
  11. Install the new input shaft seal with Installer 9672 and Handle C-4171.
    Fig 9: Removing/Installing Retainer at Mode Hub
    GC0006010Courtesy of DAIMLERCHRYSLER CORP.
    1 - MODE HUB RETAINER
    2 - MODE HUB
  12. Lubricate mainshaft splines with recommended transmission fluid.
    NOTE: Replace the mode hub retainer if the legs were distorted during removal.
  13. Install the mode hub retainer (2) onto the mode hub (1). See Fig 9.
    Fig 10: Removing/Installing Mode Hub and Retainer
    GC0006009Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL ASSEMBLY
    2 - MODE HUB AND RETAINER
  14. Install the mode hub (2) and mode hub retainer onto the differential assembly (1). Make sure the retainer is fully seated onto the differential. See Fig 10.
    Fig 11: Remove/Install the Differential
    GC0027418Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL ASSEMBLY
    2 - MAINSHAFT
  15. Install the differential assembly (1) onto the mainshaft (2). See Fig 11.
    Fig 12: Remove/Install the Differential Snap-ring
    GC0027417Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL SNAP-RING
  16. Install the differential snap-ring (1). See Fig 12.
    Fig 13: Remove/Install Chain Guide
    GC0027424Courtesy of DAIMLERCHRYSLER CORP.
    1 - DRIVE CHAIN GUIDE
  17. Install the drive chain guide (1) onto the transfer case. See Fig 13.
    Fig 14: Remove/Install Chain Guide Screws
    GC0027423Courtesy of DAIMLERCHRYSLER CORP.
    1 - SCREWS
    2 - FRONT CASE
  18. Install the screws (1) to hold the chain guide rail to the front case (2). Tighten the screws to 5-8 N.m (44-71 in.lbs.). See Fig 14.
    Fig 15: Remove/Install Input Gear Thrust Washer
    GC0027427Courtesy of DAIMLERCHRYSLER CORP.
    1 - THRUST WASHER
    2 - INPUT GEAR
  19. Install the input gear thrust washer (1) onto the input gear (2). See Fig 15.
    Fig 16: Remove/Install Mainshaft and Differential Assembly
    GC0027416Courtesy of DAIMLERCHRYSLER CORP.
    1 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY
    2 - FRONT HOUSING
    NOTE: Be sure that the input spline is engaged with the differential assembly.
  20. Install the mainshaft and differential assembly (1) into the front case (2) and input gear. See Fig 16.
    Fig 17: Remove/Install Front and Rear Drive Sprockets and Drive Chain
    GC0027415Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT DRIVE SPROCKET
    2 - MAINSHAFT DRIVE SPROCKET
    3 - DRIVE CHAIN
  21. Install the drive sprockets (1, 2) and drive chain (3) as one. See Fig 17.
    Fig 18: Front Drive Sprocket Retaining Ring Removal/Installation
    GC0027414Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  22. Install the front output shaft (1) drive sprocket retaining ring (2). See Fig 18.
    Fig 19: Mode Hub Spacer Installation/Removal
    GC0027428Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - MODE HUB SPACER
    3 - MODE HUB
  23. Install the mode hub spacer (2). See Fig 19onto the output shaft (1) and the mode hub (3).
  24. Install the mainshaft drive sprocket retaining ring onto the mainshaft.
    Fig 20: Remove/Install Rear Housing
    GC0027422Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - FRONT HOUSING
  25. Install the transfer case magnet into the magnet pocket.
  26. Apply bead of Mopar® Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3 mm (0.125 inch). Do not use excessive amount of sealer as excess will be displaced into case interior.
  27. Install the rear case (1) onto the front case (2). See Fig 20.
    Fig 21: Remove/Install Rear Housing Bolts
    GC0027413Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - BOLTS
    3 - FRONT HOUSING
  28. Install the bolts (2) to hold the rear case (1) to the front case (3). Tighten the bolts at the alignment dowel locations first. Tighten the bolts to 27 N.m (20 ft.lbs.). See Fig 21.
    Fig 22: Remove/Install Rear Output Shaft Flange
    GC0027412Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR OUTPUT SHAFT FLANGE
    2 - REAR OUTPUT SHAFT
  29. Install a new rear output seal into the rear case with Installer C-3972A.
  30. Install the rear output flange (1) onto the output shaft (2). See Fig 22.
    Fig 23: Remove/Install Rear Output Shaft Nut
    GC0027411Courtesy of DAIMLERCHRYSLER CORP.
    1 - HOLDER C-3281
    2 - REAR OUTPUT SHAFT FLANGE
  31. Using Holder C-3281 (1), install the rear companion flange (2) nut. Tighten the bolts to 122-176 N.m (90-130 ft.lbs.). See Fig 23.
    Fig 24: Remove/Install Damper
    GC0027426Courtesy of DAIMLERCHRYSLER CORP.
    1 - DAMPER
    2 - REAR HOUSING
  32. Install the transfer case damper (1) onto the rear case (2). See Fig 24.
    Fig 25: Remove/Install Damper Bolts
    GC0027425Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLTS
    2 - DAMPNER
    3 - REAR HOUSING
  33. Install the bolts (1) to hold the damper (2) to the rear case (3). Tighten the bolts to 27 N.m (20 ft.lbs.). See Fig 25.
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