Page 4105 of 5267
10. The bearing bore is chamfered (1) at the top.
Install the bearing so it is flush with the lower
edge of this chamfer.
11. Remove the rear output shaft bearing from the
rear case using Bearing Installer 8684 (2) and
Universal Handle C-4171 (3).
12. Install the rear output shaft bearing into the rear
case (1) using Bearing Installer 6953 (2) and Uni-
versal Handle C-4171 (3).
Page 4106 of 5267
INPUT AND PLANETARY GEAR
1. Lubricate gears (3, 4) and thrust washers (5) with
recommended transmission fluid.
2. Install first thrust washer (5) in low range gear (3).
Be sure washer tabs are properly aligned in gear
notches.
3. Install input gear (3) in low range gear (4). Be sure
input gear is fully seated.
4. Install remaining thrust washer (5) in low range
gear (4) and on top of input gear (3). Be sure
washer tabs are properly aligned in gear notches.
5. Install retainer (2) on input gear and install snap-
ring (1).
6. Align and install low range/input gear assembly (2)
in front case (1). Be sure low range gear pinions
are engaged in annulus gear and that input gear
shaft is fully seated in front bearing.
7. Install snap-ring (2) to hold input/low range gear (1)
into front bearing.
8. Install a new input gear seal using Seal Installer
8841 and Universal Handle C-4171.
Page 4107 of 5267
SHIFT FORKS AND MAINSHAFT
1. Lubricate mainshaft splines with recommended
transmission fluid.
2. Install the mode hub (1) onto the output shaft.
3. Install the mode hub retaining ring (2) onto the out-
put shaft (1).
4. Install the sprocket hub (2) onto the output shaft
(1).
Page 4108 of 5267
5. Install the clutch gear (2) onto the output shaft (1).
6. Install the drive sprocket (2) onto the output shaft
(1).
7. Install the drive sprocket (3) thrust washer (2) onto
the output shaft (1).
Page 4109 of 5267
8. Install the drive sprocket retaining ring (2) onto the
output shaft (1).
9. Lubricate sector shaft with transmission fluid and
install shift sector (1) in case. Position slot in sector
so it will be aligned with shift fork pin when shift
forks are installed.
10. Install the shift sector support (1). Tighten the sec-
tor support to 27-42 Nꞏm (20-30 ft.lbs.).
Page 4110 of 5267
11. Assemble and install range fork (2) and hub (1).
Be sure hub is properly seated in low range gear
and engaged to the input gear.
12. Align and insert range fork pin in shift sector slot.
13. Install the range fork retaining ring.
14. Install mode fork (1) and shift rail (2) onto the
mode sleeve (3).
15. Install the mode fork, sleeve, and shift rail into the
transfer case.
16. Install mainshaft (2) into the transfer case (1).
Guide mainshaft through the mode and range
sleeves and into the input gear.
Page 4111 of 5267
17. Install the transfer case position sensor or switch
(2). Tighten the sensor or switch to 20-34 Nꞏm
(16-25 ft. lbs.) torque.
18. Install range lever (1) on sector shaft.
19. Install washer and nut on sector shaft to secure
shift lever. Apply 1-2 drops Mopar
Lock N’ Seal,
or equivalent, to nut threads before installation.
Then tighten nut to 27-34 Nꞏm (20-25 ft. lbs.)
torque.
20. Install new o-ring on detent plug (2).
Page 4112 of 5267
21. Install detent plunger (4), spring (3), and plug (2).
Tighten the plug to 16-25 Nꞏm (12-18 ft. lbs.).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Install the front output shaft (2) into the front output
shaft bearing.
2. Install the front output shaft retaining ring (2) onto
the output shaft.
3. Install the new front output shaft seal with Seal
Installer MB991168A.