Disassembly And Assembly

DISASSEMBLY 

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1. Remove the rear output flange nut (1) and remove the rear output flange (2). If necessary, use a suitable 2 or 3 jaw puller to remove the output flange.

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2. Remove encoder screws and the encoder from the transfer case.

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3. Remove the shift shaft snap ring (1) from the transfer case.

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4. Remove shift motor bolts (1) and remove the shift motor (2).

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5. Remove the transfer case bolts and studs (1) and separate the case halves.
   NOTE:

   Some prying may be necessary to break the seal between the front and rear case. Use care to not damage the sealing surfaces.

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6. Remove the output shaft thrust washer.

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7. Remove the oil pump assembly.

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8. Remove the pick-up magnet from the magnet pocket.
   NOTE:

   For ease of installation note the orientation of the worm shaft drive gear inner splines to the shift shaft outer splines.

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9. Remove the worm drive gear.
   NOTE:

   For ease of installation note the orientation of the clutch cam inner splines to the shift shaft outer splines.

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10. Remove the clutch cam.

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11. Remove the clutch upper snap ring.

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12. Remove the clutch shim.

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13. Remove the thrust collar.

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14. Remove the upper thrust bearing race.

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15. Remove the upper thrust bearing.

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16. Remove the upper shift lever.

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17. Remove the shift lever balls.

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18. Remove the lower shift lever.

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19. Remove the lower thrust bearing.

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20. Remove the lower thrust bearing race.

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21. Remove the clutch apply piston.

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22. Remove the clutch return spring.

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23. Remove the clutch pack.

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24. Remove the clutch drum thrust washer (1).

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25. Remove the welded front drive sprocket and drum assembly, drive chain, and driven sprocket as one.

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26. Remove the shift shaft spacer.

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27. Remove the shift shaft.

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28. Remove the main shaft from the transfer case.

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29. Remove the retaining snap ring from the front output shaft.

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30. Remove the front output shaft from the transfer case.

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31. Using a suitable pry tool or a screw mounted in a slide hammer, remove the input gear seal. Remove and discard the input gear snap ring (1).

ASSEMBLY 

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1. While holding the retaining ring tabs apart with suitable snap-ring pliers, remove the input shaft bearing (1) from the front case (2).
2. Transfer the retaining ring to the new housing, if necessary, and install the bearing into the front case.

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3. Using a suitable pry tool or a screw mounted in a slide hammer, remove the front output shaft seal.
4. Using (special tool #6061, Installer, Cup) inverted, and (special tool #C-4171, Driver Handle, Universal), remove front output shaft bearing.
5. Start front output shaft bearing in case (2). Then seat bearing with (special tool #C-4171, Driver Handle, Universal) (3) and (special tool #C-4210, Installer, Seal) (2).
6. Install the front output shaft seal using (special tool #6560, Installer, Bearing Cup).

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7. Using a suitable pry tool or a screw mounted in a slide hammer, remove the rear output shaft seal.
8. Remove the rear output shaft bearing from the rear case using (special tool #L-4408, Installer, Bearing) (2) inverted and (special tool #C-4171, Driver Handle, Universal) (1).
9. Install the rear output shaft bearing into the rear case using (special tool #6061, Installer, Cup) inverted and (special tool #C-4171, Driver Handle, Universal).

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10. Remove shift shaft bearing snap ring.

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11. Remove shift shaft bearing using (special tool #C-4171, Driver Handle, Universal) (1) and (special tool #5066, Installer, Bushing) (2).

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12. Install shift shaft bearing using (special tool #C-4171, Driver Handle, Universal) (1) and (special tool #5066, Installer, Bushing) (2) inverted.

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13. Install shift shaft bearing snap ring.

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14. Remove front output shaft rear bearing from housing using (special tool #7794-A, Remover, Seal) (1) and (special tool #C-637, Slide Hammer, Universal) (2).

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15. Install front output shaft rear bearing in housing using (special tool #6061, Installer, Cup) (2) inverted and (special tool #C-4171, Driver Handle, Universal) (1).

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16. Install the front output shaft flange into the front housing.

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17. Install the front output shaft snap ring.

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18. Install the input gear snap ring.

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19. Using (special tool #9672, Installer, Seal) (2) and (special tool #C-4171, Driver Handle, Universal) (1), install a new input shaft seal.

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20. Install the main shaft into the transfer case.

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21. Install the shift shaft.

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22. Install the shift shaft spacer.

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    NOTE:

    There is a blue link on one side of the chain. This blue link MUST be installed facing upward.

23. Install the welded front drive sprocket and drum assembly, drive chain, and driven sprocket as one.

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24. Install the clutch drum thrust washer (1).

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25. Starting with a friction disc and ending with a friction disc, install the clutch pack.

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26. Install the clutch return springs.

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27. Install the clutch apply piston with the lettering up and the stepped face down.

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28. Install the lower bearing race with the race fitting into the grove in the reaction plate.

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29. Install the lower bearing.

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30. Install the lower shift lever.

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31. Install the shift lever balls into their pockets.

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32. Install the upper shift lever.

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33. Install the upper thrust bearing.

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34. Install the upper bearing race.

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35. Install the thrust collar.

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36. Install the clutch shim.

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37. Install clutch upper snap ring.
    NOTE:

    The clutch cam has the word "FRONT" stamped into. This identifies the orientation of the clutch cam to the front of the transfer case. Before installing the clutch cam, note the orientation of the clutch cam inner splines to the outer splines on the shift shaft. Install it such that the roller falls into low point of clutch cam.

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38. Install the clutch cam.
    NOTE:

    Before installing the worm drive gear, note the orientation of the worm drive gear inner splines to the outer splines on the shift shaft.

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39. Install the worm drive gear.

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40. Install the magnet into the magnet pocket.

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41. Install the oil pump assembly.

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42. Install the output shaft thrust washer.

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    NOTE:

    Do not use excessive amount of sealer as excess could be displaced into the oil pump. Keep sealer bead width to maximum of 3 mm (1/8 inch).

43. Apply bead of Mopar® Gasket Maker, or equivalent, to one of the mating surfaces of the front or rear housing.
44. Install the rear housing onto the front housing. Install the housing bolts. Tighten housing bolts in a crisscross pattern to the proper specification. Refer to TORQUE SPECIFICATIONS  .
    CAUTION:

    Carefully align and thread (rotate counterclockwise) the worm shaft to install it into the transfer case. Failure to follow this caution may result in parts damage.

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45. Install the worm shaft into the transfer case.
    NOTE:

    It may be necessary to apply slight inward pressure on the worm shaft to seat the snap ring.

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46. Install the worm shaft snap ring.

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47. Using a suitable installer, install the shift motor seal.

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48. Install a NEW  O-ring onto the shift motor.

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    NOTE:

    Note the orientation of the shift motor shaft to the worm gear shaft.

49. Install the shift motor onto the transfer case. Install the shift motor bolts. Tighten the shift motor bolts to the proper specification. Refer to TORQUE SPECIFICATIONS  .

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    NOTE:

    It may be necessary to pull out on the shift shaft to properly seat the shift shaft snap ring.

50. Install the shift shaft snap ring.

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51. Align arrow (1) on the encoder shaft with alignment mark (2) prior to installing the encoder.
    NOTE:

    Before installing the encoder onto the transfer case, be certain to align the encoder shaft to the shift shaft and the dowel on the encoder to the hole in the case accordingly.

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52. Install the encoder onto the rear transfer case housing. Install the encoder screws. Tighten the screws to the proper specification. Refer to TORQUE SPECIFICATIONS  .

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53. Using the (special tool #2049400210, Installer, Output Shaft Oil Slinger) (2) and (special tool #C-4171, Driver Handle, Universal) (3) install the NEW  output shaft oil slinger seal (1).

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54. Install the companion flange (2) with a NEW  pinion flange nut and tighten to the proper specification. Refer to TORQUE SPECIFICATIONS  .

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55. Using (special tool #C-3281, Holder, Flange) (1), install the rear output flange with a NEW  rear output flange nut (1) and tighten the nut to the proper specification. Refer to TORQUE SPECIFICATIONS  .