Service Information: Assembly

Fig 1: Install Intermediate Gear Rear Bearing Race

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1 - REAR HOUSING

2 - HANDLE C-4171

3 - INSTALLER D-130

1. Install the intermediate gear rear bearing race into the rear housing (1) with Handle C-4171 (2) and Installer D-130 (3). See Fig 1.
   Fig 2: Install Intermediate Gear Front Bearing Race

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   1 - FRONT HOUSING

   2 - HANDLE C-4171

   3 - INSTALLER D-130

2. Install the intermediate gear front bearing race into the front housing (1) with Handle C-4171 (2) and Installer D-130 (3). See Fig 2.
   Fig 3: Install Hollow Shaft Front Bearing Race

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   1 - FRONT HOUSING

   2 - HANDLE C-4171

   3 - INSTALLER C-4308

3. Install the hollow shaft front bearing race into the front housing (1) with Handle C-4171 (2) and Installer C-4308 (3). See Fig 3.
   Fig 4: Install Hollow Shaft Rear Bearing Race

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   1 - REAR HOUSING

   2 - HANDLE C-4171

   3 - INSTALLER D-145

4. Install the hollow shaft rear bearing race into the rear housing (1) with Handle C-4171 (2) and Installer D-145 (3). See Fig 4.
   Fig 5: Install Front Output Shaft Front Bearing Race

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   1 - FRONT HOUSING

   2 - HANDLE C-4171

   3 - INSTALLER D-130

5. Install the front output shaft front bearing race into the front housing (1) with Handle C-4171 (2) and Installer D-130 (3). See Fig 5.
   Fig 6: Install Front Output Shaft Rear Bearing Race

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   1 - REAR HOUSING

   2 - HANDLE C-4171

   3 - INSTALLER D-130

6. Install the front output shaft rear bearing race into the rear housing (1) with Handle C-4171 (2) and Installer D-130 (3). See Fig 6.
   Fig 7: Install Front Output Shaft Front Bearing

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   1 - INSTALLER C-3717

   2 - BEARING

   3 - FRONT OUTPUT GEAR

7. Install the front output shaft front bearing (2) onto the front output gear (3) with Installer C-3717 (1). See Fig 7.
   Fig 8: Install Front Output Shaft Rear Bearing

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   1 - HANDLE C-4171

   2 - INSTALLER L-4410

   3 - FRONT OUTPUT GEAR

8. Install the front output shaft rear bearing onto the front output gear (3) with Handle C-4171 (1) and Installer L-4410 (2). See Fig 8.
   Fig 9: Install Intermediate Gear Bearing

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   1 - HANDLE C-4171

   2 - INSTALLER L-4410

   3 - INTERMEDIATE GEAR

9. Install the front and rear bearings onto the intermediate gear (3) with Handle C-4171 (1) and Installer L-4410 (2). See Fig 9.
   Fig 10: Install Hollow Gear Front Bearing

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   1 - HANDLE C-4171

   2 - INSTALLER C-4213

   3 - HOLLOW SHAFT

10. Install the front bearing onto the hollow shaft (3) with Handle C-4171 (1) and Installer C-4213 (2). See Fig 10.
11. Install the rear bearing onto the hollow shaft with Installer 9679.
    Fig 11: Install Input Gear Seal

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    1 - FRONT HOUSING

    2 - INSTALLER 8891

12. Install a new front output shaft seal into the front housing with Installer MD998334.
    NOTE: Apply a light coating of oil to both the inner lip and outer surface of the new oil seal.
13. Install a new input gear seal in the front housing (1) using Installer 8891 (2). See Fig 11.
    Fig 12: Input Gear Thrust Washer

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    1 - INPUT SHAFT

    2 - THRUST WASHER

    3 - HOLLOW SHAFT

14. Set the hollow shaft in position in the front housing.
15. Install the input shaft through the front seal and the hollow shaft.
16. Install the input gear thrust washer (2) onto the input shaft (1) and hollow shaft (3). See Fig 12.
    Fig 13: Input Gear Snap-Ring

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    1 - INPUT SHAFT

    2 - SNAP-RING

    3 - HOLLOW SHAFT

17. Install the snap-ring (2) to hold the input shaft (1) in the hollow shaft (3). See Fig 13.
    Fig 14: Intermediate Gear

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    1 - INTERMEDIATE GEAR

    2 - FRONT HOUSING

18. Install the intermediate gear (1) into the front housing (2). See Fig 14.
    Fig 15: Front Output Shaft

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    1 - FRONT OUTPUT SHAFT

    2 - FRONT HOUSING

19. Install the front output shaft (1) into the front housing (2). See Fig 15.
    Fig 16: Rear Housing

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    1 - REAR HOUSING

    2 - FRONT HOUSING

20. Clean the mating surfaces of the transfer case housings.
21. Apply a 2 mm (0.08 in.) bead of MOPAR® Gasket Maker around the perimeter of the front housing.
22. Set the rear housing (1) onto the front housing (2). See Fig 16.
    Fig 17: Rear Housing Bolts

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    1 - BOLTS

    2 - REAR HOUSING

23. Install the bolts (1) to hold the rear housing (2) to the front housing. Tighten the bolts in a cross pattern to 34 N.m (25 ft.lbs.) for the 30 and 45 mm long bolts. See Fig 17.
24. Using locally acquired nuts, install the 120 mm long bolts through the transfer case and install the nuts to the bolts. Tighten the nuts to 10 N.m (7.5 ft.lbs.). Leave the 120 mm bolts torqued this way for a minimum of 30 minutes to ensure that the sealant has cured properly. After the 30 minutes, the 120 mm bolts can be removed.
    Fig 18: Planetary Gear System

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    1 - PLANETARY GEAR SYSTEM

    2 - REAR HOUSING

25. Install the planetary gear system (1) into the transfer case rear housing (2). See Fig 18.
    Fig 19: Snap-Ring

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    1 - INPUT SHAFT

    2 - SNAP-RING

    3 - PLANETARY GEAR SYSTEM

26. Install the snap-ring (2) to hold the input shaft (1) to the planetary gear system (3). See Fig 19.
    Fig 20: Output Shaft

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    1 - OUTPUT SHAFT

    2 - PLANETARY GEAR SYSTEM

    3 - TRANSFER CASE REAR HOUSING

27. Install the output shaft (1) into the planetary gear system (2). See Fig 20.
    Fig 21: Rear Output Shaft Bearing Snap-Ring

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    1 - SNAP-RING

    2 - TRANSFER CASE COVER

28. Install the output shaft bearing into the cover using a suitable drift tool.
29. Install the rear output shaft bearing snap-ring (1) into the transfer case cover (2). See Fig 21.
    Fig 22: Transfer Case Cover

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    1 - TRANSFER CASE COVER

    2 - TRANSFER CASE

30. Clean the mating surfaces of the transfer case cover and the rear housing.
31. Apply a 2 mm (0.08 in.) bead of MOPAR® Gasket Maker around the perimeter of the rear housing.
32. Position the transfer case cover (1) onto the transfer case (2). See Fig 22.
    Fig 23: Transfer Case Cover Bolts

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    1 - OUTPUT SHAFT

    2 - TRANSFER CASE COVER

    3 - BOLTS

33. Install the bolts (3) to hold the transfer case rear cover (2) to the transfer case. Tighten the bolts in a cross pattern to 34 N.m (25 ft.lbs). See Fig 23.
    Fig 24: Install Rear Output Shaft Seal

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    1 - INSTALLER C-3860A

    2 - TRANSFER CASE COVER

34. Install the rear output shaft seal from the transfer case cover (2) with Installer C-3860A (1). See Fig 24.
    Fig 25: Rear Output Flange

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    1 - TRANSFER CASE

    2 - REAR OUTPUT SHAFT FLANGE

    NOTE: For the most accurate torque reading, apply a light coating of oil to the nut face that contacts the flange and to the flange splines.
35. Install the rear output shaft flange (2) onto the output shaft. Install a new nut. See Fig 25.
    Fig 26: Rear Output Flange Nut

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    1 - HOLDER 6958

    2 - REAR OUTPUT SHAFT FLANGE

36. Install Holder 6958 (1) onto the rear output flange (2). See Figure.
37. Tighten the rear output flange nut to 250 N.m (185 ft.lbs.).
    Fig 27: Front Output Flange Nut

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    1 - HOLDER 6958

    2 - FRONT OUTPUT SHAFT FLANGE

38. Install the front output shaft flange onto the front output shaft. Install a new nut.
39. Install Holder 6958 (1) onto the front output flange (2). See Fig 27.
40. Tighten the front output flange nut to 250 N.m (185 ft.lbs.).