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Service Information: Assembly

Fig 1: Remove Input Gear Bearing
GC0005867Courtesy of DAIMLERCHRYSLER CORP.
1 - INPUT GEAR BEARING
2 - FRONT CASE
  1. While holding the retaining ring tabs apart with suitable snap-ring pliers, remove the input shaft bearing (1) from the front case (2). See Fig 1.
  2. Transfer the retaining ring to the new housing, if necessary, and install the bearing into the front case.
    Fig 2: Install Front Output Shaft Bearing
    GC0027480Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT CASE
    2 - INSTALLER C-4210
    3 - HANDLE C-4171
  3. Using Installer 6436 and Handle C-4171, remove front output shaft bearing.
  4. Start front output shaft bearing in case. Then seat bearing with Handle C-4171 (3) and Installer C-4210 (2). See Fig 2.
    Fig 3: Install Rear Output Shaft Bearing
    GC0027479Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR CASE
    2 - REMOVER/INSTALLER 5066
    3 - HANDLE C-4171
  5. Remove the rear main shaft bearing retaining ring from inside the rear housing.
  6. Remove the rear output shaft bearing from the rear case using Installer 5066 (2) and Handle C-4171 (3). See Fig 3.
  7. Install the rear output shaft bearing into the rear case using Remover/Installer 8281 (2) and Handle C-4171 (3).
  8. Install the rear output shaft bearing retaining ring into the rear housing, from inside the rear housing.
    Fig 4: Bottom Thrust Washer Removal/Installation
    GC0027477Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOTTOM THRUST WASHER (3 TABS)
    2 - LOW RANGE PLANETARY
  9. Install the bottom thrust washer (3 tabs) (1) into the low range planetary (2). See Fig 4.
    Fig 5: Top Thrust Washer Removal/Installation
    GC0027476Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR
    2 - THRUST WASHER (NO TABS)
  10. Install the top thrust washer (no tabs) (2) onto the input gear (1). See Fig 5.
    Fig 6: Low Gear and Lock Plate Removal/Installation
    GC0027475Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR
    2 - LOCK PLATE
    3 - LOW RANGE PLANETARY
  11. Install the input gear (1) and lock plate (2) into the low range planetary (3) and install the lock plate. See Fig 6.
    Fig 7: Low Range Snap-ring Removal/Installation
    GC0027474Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR
    2 - SNAP-RING
    3 - LOW RANGE PLANETARY
  12. Install the snap-ring (2) to hold the input gear (1) into the low range planetary (3). See Fig 7.
    Fig 8: Input Planetary Assembly Removal/Installation
    GC0027468Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR AND LOW RANGE PLANETARY
  13. Install the input gear and low range planetary assembly (1) into the front housing. See Fig 8.
    Fig 9: Removing/Installing Input Gear Retaining Ring
    GC0005865Courtesy of DAIMLERCHRYSLER CORP.
    1 - INPUT GEAR
    2 - RETAINING RING
  14. Install the retaining ring (2) holding the input gear assembly into the front housing. See Fig 9.
  15. Install the new input shaft seal with Installer 9672 and Handle C-4171.
    Fig 10: Sector Shaft Removal/Installation
    GC0027472Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT HOUSING
    2 - SHIFT SECTOR
  16. Install the shift sector (2) into the rear housing (1). See Fig 10.
    Fig 11: Sector Shaft Retaining Ring Removal/Installation
    GC0027471Courtesy of DAIMLERCHRYSLER CORP.
    1 - SHIFT SECTOR
    2 - RETAINING RING
  17. Install the retaining ring (2) onto the shift sector shaft (1). See Fig 11.
    Fig 12: Oil Pump Pick-up Tube O-ring Removal/Installation
    GC0027470Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - O-RING
  18. Install the oil pick-up tube o-ring (2) into the rear housing (1). See Fig 12.
    Fig 13: Oil Pump Pick-up Tube and Screen Removal/Installation
    GC0027469Courtesy of DAIMLERCHRYSLER CORP.
    1 - OIL PICK-UP TUBE AND SCREEN
  19. Prime the oil pickup tube by pouring a little oil into the tube before installation.
  20. Install the oil pick-up tube and screen (1) into the rear housing. See Fig 13.
    Fig 14: Remove/Install Front Output Shaft and Flange
    GC0027421Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT HOUSING
    2 - FRONT OUTPUT SHAFT
  21. Install a new front output shaft seal with Installer 6560.
  22. Install the front output shaft (2) into the front housing (1) and the front output shaft front bearing. See Fig 14.
    Fig 15: Remove/Install Front Output Shaft Retaining Ring
    GC0027420Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  23. Install the retaining ring (2) onto the front output shaft (1). See Fig 15.
    Fig 16: Range Fork and Sleeve Removal/Installation
    GC0027467Courtesy of DAIMLERCHRYSLER CORP.
    1 - RANGE FORK
    2 - RANGE HUB
    NOTE: Check that all three shift pads are present and in good condition on the shift fork.
  24. Install the range fork and range hub as one into the input gear/low range planetary. See Fig 16.
    Fig 17: Removing/Installing Retainer at Mode Hub
    GC0006010Courtesy of DAIMLERCHRYSLER CORP.
    1 - MODE HUB RETAINER
    2 - MODE HUB
  25. Lubricate mainshaft splines with recommended transmission fluid.
    NOTE: Replace the mode hub retainer if the legs were distorted during removal.
  26. Install the mode hub retainer (1) onto the mode hub (2). See Fig 17.
    Fig 18: Removing/Installing Mode Hub and Retainer
    GC0006009Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL ASSEMBLY
    2 - MODE HUB AND RETAINER
  27. 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 18.
    Fig 19: Removing/Installing Differential
    GC0006008Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL ASSEMBLY
    2 - MAINSHAFT
  28. Install the differential assembly (1) onto the mainshaft (2). See Fig 19.
    Fig 20: Removing/Installing Differential Snap Ring
    GC0006007Courtesy of DAIMLERCHRYSLER CORP.
    1 - DIFFERENTIAL SNAP-RING
  29. Install the differential snap-ring (1). See Fig 20.
    Fig 21: Removing/Installing Intermediate Clutch Shaft
    GC0006006Courtesy of DAIMLERCHRYSLER CORP.
    1 - INTERMEDIATE CLUTCH SHAFT
  30. Install the intermediate clutch shaft (1). See Fig 21.
    Fig 22: Remove/Install Intermediate Clutch Shaft Thrust Ring
    GC0006005Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH SHAFT THRUST RING
  31. Install the clutch shaft thrust ring (1). See Fig 22.
    Fig 23: Removing/Installing Intermediate Clutch Shaft Snap Ring
    GC0006004Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
    2 - INTERMEDIATE CLUTCH SHAFT
  32. Install clutch shaft (2) snap-ring (1). See Fig 23.
    Fig 24: Mainshaft and Differential Assembly Removal/Installation
    GC0027466Courtesy of DAIMLERCHRYSLER CORP.
    1 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY
    2 - FRONT HOUSING
  33. Install the mainshaft and differential assembly (1) into the front housing (2), range sleeve, and input gear/low range planetary. See Fig 24.
    Fig 25: Remove Chain Guide
    GC0027465Courtesy of DAIMLERCHRYSLER CORP.
    1 - DRIVE CHAIN GUIDE
  34. Install the drive chain guides (1) onto the transfer case. See Fig 25.
    Fig 26: Chain Guide Bolts Removal/Installation
    GC0027464Courtesy of DAIMLERCHRYSLER CORP.
    1 - CHAIN GUIDE RAIL
    2 - SCREWS
  35. Install the screws (2) to hold the chain guide rails (1) to the front housing. Tighten the screws to 5-8 N.m (44-71 in.lbs.). See Fig 26.
    Fig 27: Front and Rear Drive Sprockets and Drive Chain Removal/Installation
    GC0027463Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT DRIVE SPROCKET
    2 - MAINSHAFT DRIVE SPROCKET
    3 - DRIVE CHAIN
  36. Install the front drive sprocket (1), mainshaft drive sprocket (2), and drive chain (3) as one. See Fig 27.
    Fig 28: Front Drive Sprocket Retaining Ring Removal/Installation
    GC0027414Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT OUTPUT SHAFT
    2 - RETAINING RING
  37. Install the front drive sprocket retaining ring (2) onto the front output shaft (1). See Fig 28.
    Fig 29: Clutch Assembly Removal/Installation
    GC0027462Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - CLUTCH ASSEMBLY
  38. Install the clutch assembly (2) onto the main shaft (1). See Fig 29.
    Fig 30: Wavy Spring Assembly Removal/Installation
    GC0027461Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - WAVY SPRING
  39. Install the wave spring (2) onto the main shaft (1). See Fig 30.
    Fig 31: Clutch Pressure Plate Removal/Installation
    GC0027460Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - CLUTCH PRESSURE PLATE
    CAUTION: When installing the clutch pressure plate, make sure that the wave spring remains piloted on the underside of the plate. Check that the spring does not protrude between the plate and the mainshaft.
  40. Install the clutch pressure plate (2) onto the main shaft (1) and clutch assembly. See Fig 31.
    Fig 32: Thrust Bearing Removal/Installation
    GC0027459Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - THRUST BEARING
  41. Install the thrust bearing (2) onto the main shaft (1). See Fig 32.
    Fig 33: Thrust Bearing Support Plate Removal/Installation
    GC0027458Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - SUPPORT PLATE
  42. Install the thrust bearing support plate (2) onto the main shaft (1). See Fig 33.
    Fig 34: Thrust Bearing Support Plate Retaining Ring Removal/Installation
    GC0027457Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - RETAINING RING
    NOTE: The clutch pressure plate must be engaged with the inner drum and held down when installing the retaining ring.
  43. Install the thrust bearing support plate retaining ring (2) onto the main shaft (1). See Fig 34.
    Fig 35: Align Tabs on the Bearing Support Plate
    GC0044479Courtesy of DAIMLERCHRYSLER CORP.
    1 - SUPPORT PLATE
    2 - TAB
    3 - BOLT HOLES
  44. Rotate the thrust bearing support plate (1) so that the tab (2) is pointed between the two bolt holes (3) as shown. See Fig 35.
    Fig 36: Clutch Lever Assembly Removal/Installation
    GC0027456Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH LEVER ASSEMBLY
  45. Install the clutch lever assembly (1) onto the mainshaft and shift rail. See Fig 36.
    Fig 37: Rear Housing Removal/Installation
    GC0027455Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - FRONT HOUSING
  46. 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 and potentially clog the oil pump screen. 
  47. Verify that the tab on the thrust bearing support plate is aligned with the housing alignment dowel furthest from the front output shaft.
  48. Install the rear housing (1) into the front housing (2). See Fig 37.
    Fig 38: Rear Housing Bolts Removal/Installation
    GC0027451Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - BOLTS
    3 - FRONT HOUSING
  49. Install the bolts (2) to hold the rear housing (1) to the front housing (3). Tighten the bolts at the dowel locations first, then the remainder of the bolts in a criss-cross pattern. Tighten the bolts to 27 N.m (20 ft.lbs.). See Fig 38.
    Fig 39: Rear Output Bearing Inner Retaining Ring Removal/Installation
    GC0027454Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - RETAINING RING
    3 - REAR HOUSING
    NOTE: Pull up on the main shaft when installing the retaining ring to ensure that the ring is fully engaged into the groove.
  50. Install the rear main shaft (1) retaining ring (2). See Fig 39.
    Fig 40: Oil Pump Outer Rotor Removal/Installation
    GC0027453Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - OIL PUMP OUTER ROTOR
    3 - REAR HOUSING

    Lubricate the oil pump components with transmission fluid before installation.

  51. Install the oil pump outer rotor (2) onto the main shaft (1) and into the rear housing (3). See Fig 40.
    Fig 41: Oil Pump Inner Rotor Removal/Installation
    GC0027452Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT
    2 - OIL PUMP INNER ROTOR
    3 - REAR HOUSING
  52. Install the oil pump inner rotor (2) onto the main shaft (1) and into the rear housing (3). See Fig 41.
    Fig 42: Clutch Lever Rail Removal/Installation
    GC0027450Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - CLUTCH LEVER RAIL
  53. Install the clutch lever rail (2) into the rear housing (1) and clutch lever. See Fig 42.
    Fig 43: Clutch Lever Rail Plug Removal/Installation
    GC0027449Courtesy of DAIMLERCHRYSLER CORP.
    1 - CLUTCH LEVER RAIL PLUG
  54. Install the clutch lever rail plug (1) into the rear housing. See Fig 43.
    Fig 44: Anti-Rotation Bracket Removal/Installation
    GC0027448Courtesy of DAIMLERCHRYSLER CORP.
    1 - ANTI-ROTATION BRACKET
    2 - SHIFT RAIL
  55. Install the anti-rotation bracket (1) onto the shift rail (2). See Fig 44.
    Fig 45: Sector Roller Removal/Installation
    GC0027447Courtesy of DAIMLERCHRYSLER CORP.
    1 - SECTOR ROLLER
    2 - SHIFT RAIL
  56. Install the sector roller (1) onto the shift rail (2). See Fig 45.
  57. Using a suitable punch, align the holes in the sector roller with the hole in the shift rail and install the roll-pin to secure the sector roller to the shift rail.
    Fig 46: Sealant Application Pattern
    GC0027478Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - SEALANT
  58. Apply bead of Mopar® Gasket Maker, or equivalent, to mating surface of rear housing as shown (2). See Fig 46. Keep sealer bead width to maximum of 3 mm (1/8 inch). Do not use excessive amount of sealer as excess could be displaced into the oil pump.
    Fig 47: Rear Retainer Removal/Installation
    GC0027445Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR COVER
    2 - REAR HOUSING
  59. Install a new rear output shaft seal into the rear cover with Installer C-3972A.
  60. Install the rear cover (1) onto the rear housing (2). See Fig 47.
    Fig 48: Rear Retainer Bolts Removal/Installation
    GC0027444Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR HOUSING
    2 - REAR COVER
    3 - BOLTS
  61. Install the bolts (3) holding the rear cover (2) onto the rear housing (1). Tighten the bolts at the dowel locations first, then the remainder of the bolts in a criss-cross pattern. Tighten the bolts to 27 N.m (20 ft.lbs.). See Fig 48.
    Fig 49: Shift Motor Removal/Installation
    GC0027443Courtesy of DAIMLERCHRYSLER CORP.
    1 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
    2 - SHIFT SECTOR
    3 - TRANSFER CASE
  62. Install the shift motor and mode sensor assembly (1) onto the shift sector (2) and the transfer case (3). See Fig 49.
    Fig 50: Shift Motor Bolts Removal/Installation
    GC0027442Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOLTS
    2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
  63. Install the bolts (1) to hold the shift motor and mode sensor assembly (2) to the transfer case. Tighten the bolts to 27 N.m (20 ft.lbs.). See Fig 50.
    Fig 51: Rear Output Shaft Flange Removal/Installation
    GC0027441Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR COMPANION FLANGE
    2 - OUTPUT SHAFT
  64. If necessary, install the transfer case damper onto the transfer case.
  65. Install the rear output flange (1) onto the main shaft (2). See Fig 51.
    Fig 52: Rear Output Shaft Nut Removal/Installation
    GC0027440Courtesy of DAIMLERCHRYSLER CORP.
    1 - HOLDER C-3281
    2 - REAR COMPANION FLANGE
  66. Using Holder C-3281 (1), install the rear output flange (2) nut. Tighten the bolts to 122-176 N.m (90-130 ft.lbs.). See Figure.
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