Transfer Case - 2-Speed Torque-On-Demand: Assembly

1.

Lubricate all internal components with the recommended transfer case lubricant during reassembly.

2.

Clean the mating surfaces of the cases.

3.

Using a press and the Output Shaft Front Bearing Installer with the Handle, install the front planet support bearing.

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4.

Using a press and the Front Axle Oil Seal Installer with the Handle, install the front output shaft support bearing.

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5.

Using the Input Shaft Oil Seal Installer, install a new front output shaft seal.

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6.

Using the Valve Stem Oil Seal Installer, install a new shift shaft seal.

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7.

Install the case to the Transmission Holding Fixture. Secure the case and the Transmission Holding Fixture to the work bench.

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8.

Using Input Shaft Oil Seal Installer, install a new front input shaft seal.

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9.

Install the ring gear.
- 1.
  
  Position the ring gear in the case.
- 2.
  
  Install the snap ring.

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10.

Install the front output shaft and the snap ring.

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NOTE: If removed, using a press and the Input Shaft Bearing Installer, install the needle bearing into the front planet. Be careful not to damage the bearing cage.

11.
Install the front planet.

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12.

Install the shift fork shaft.

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13.

Assemble the reduction hub and the reduction shift fork. Install the reduction shift fork, the reduction hub and the shift cam as an assembly.

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14.

Install the output shaft.

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NOTE: Make sure the oil pump finger is in the slot in the case.

15.
Install the oil pump assembly.

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16.

Install the oil pan magnet into the slot in the case.

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17.

Install the 3-piece thrust bearing assembly.
- 1.
  
  Install the thrust washer.
- 2.
  
  Install the thrust bearing.
- 3.
  
  Install the thrust washer.

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18.

Install the drive chain and the sprockets as an assembly.

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19.

NOTE: When installing the clutch assembly, do not separate the clutch pack assembly. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem will occur.

NOTE: If the clutch pack is disassembled, a new clutch pack must be installed and the armature transferred. Failure to install a new clutch pack can result in component failure.

Install the clutch pack assembly with the armature.

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20.

Install a new snap ring.

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21.

Install the wave spring.

22.

Install the cam and the steel balls.

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23.

Install the cam/coil housing.

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24.

Install the thrust bearing assembly.

25.

Install the snap ring.

26.

Using a press and the Mainshaft Bearing Installer, install the rear output shaft support bearing.

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27.

Using a press and the Mainshaft Bearing Installer, install the front output shaft rear bearing.

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NOTE: Only apply enough silicone sealant to seal the transfer case halves together.

28.
Apply a bead of silicone sealant to the transfer case mating surface, then position the 2 transfer case halves together. Tighten the 20 transfer case bolts evenly in a star pattern.
- Position the coil studs through the case holes, making sure the shift cam shaft is aligned with its case bore and the lockup shift fork spring is in position.
- Tighten to 29 Nm (21 lb-ft).

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29.

Install the 3 coil washers and nuts.
- Tighten to 10 Nm (89 lb-in).

30.

Using the Input Shaft Oil Seal Installer, install the rear output shaft seal.

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31.

Apply a small bead of silicone sealant to the transfer case shift motor mating surface.

NOTE: When installing the shift motor, tighten the bracket nuts last. Failure to follow the steps in the correct order may result in damage to the component.

32.

Install the transfer case shift motor and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).

33.

Install the transfer case shift motor bracket bolt.
- Tighten to 10 Nm (89 lb-in).

34.

Secure the transfer case shift motor bracket nuts.

NOTE: After the wire is inserted into the connector, gently pull the wire back to verify the pin is locked inside the connector.

35.
Insert the coil wire pin in the electrical connector and install the inner connector retainer.

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36.

Install the transfer case dampener and the transfer case dampener bolts.
- Tighten to 18 Nm (159 lb-ft).

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37.

Secure the transfer case to a transmission jack and remove the transfer case from the Transmission Holding Fixture.

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