1

Front Wheel Drive Intermediate Shaft

2

Front Wheel Drive Intermediate Shaft Bearing Retainers (Qty: 2)

3

Front Wheel Drive Intermediate Shaft Bearing Assembly

Tip
Use a press, with the J 22912-B flat side up, in order to install the bearing assembly.

Special Tools

J 22912-B Rear Pinion and Axle Bearing Remover

4

O-Ring

5

Half Shaft Retainer

1

Transfer Case Rear Output Shaft

2

Transfer Case Rear Output Shaft Bearing Spacer

3

Transfer Case Rear Output Shaft Housing

4

Transfer Case Rear Output Shaft Bearing Assembly

Tip
Use a press with the J 5590 to install the housing and bearings to the output shaft.

Special Tools

J 5590 Pinion Bearing Race Installer - Rear

5

Transfer Case Rear Output Shaft Seal

Tip
Use a press with the DT-48075 to install the seal.

Special Tools

DT-48075 Output Shaft Seal Installer

1

Transfer Case Rear Output Shaft Oil Slinger

Tip
Use a press with the DT-48077 in order to install the slinger.

Special Tools

DT-48077 Output Shaft Slinger Installer

2

Transfer Case Rear Output Shaft Flange

Tip
Use a press with the J 5590 to install the flange.

Special Tools

J 5590 Pinion Bearing Race Installer - Rear

3

Transfer Case Rear Output Shaft Nut

Notice: Refer to Fastener Notice in the Preface section.

Tip
Use a 30 mm socket or the J 29873 and the J-08614-A .

Tighten
235 N·m (173 lb ft)

Special Tools

1

Transfer Case Half Locating Pins

2

Transfer Case Rear Output Drive Shaft

3

Transfer Case Input Shaft

Tip
Install the input and output shafts as a set with the splines engaged.

4

Transfer Case Seal

5

Transfer Case - Right

6

Transfer Case Half Bolts (Qty: 12)

Notice: Refer to Fastener Notice in the Preface section.

Tighten
29 N·m (21 lb ft)

1

Transfer Case Rear Output Shaft Housing Seal O-Ring

2

Transfer Case Rear Output Shim

3

Transfer Case Rear Output Shaft Housing

Notice: Do not use a drive hammer when the splines are not engaged. Use of a drive hammer when the splines are not engaged will damage the output shaft teeth.

Tip

Special Tools

J 25070 Heat Gun - 500-750F

4

Transfer Case Rear Output Shaft Housing Bolts (Qty: 6)

Notice: Refer to Fastener Notice in the Preface section.

Tighten
29 N·m (21 lb ft)

1

Front Wheel Drive Intermediate Shaft

Notice: DT-48094 must be used over the intermediate shaft prior to installation in order to protect the intermediate shaft seal from damage.

Special Tools

2

Front Wheel Drive Retainer

3

Front Wheel Drive Shaft Shield

Tip
The shield is no longer required on assembly. Refer to Transfer Case Description and Operation.

1

Transfer Case O-Ring Seal

2

Transfer Case Vent Assembly

Tip
Replace the vent if damaged or blocked.

3

Drain Plug

Notice: Refer to Component Fastener Tightening Notice in the Preface section.

Tighten
39 N·m (29 lb ft)

4

Fill Plug

Tighten
39 N·m (29 lb ft)

5

Transfer Case Heat Shield

6

Transfer Case Heat Shield Bolts (Qty: 3)

Notice: Refer to Fastener Notice in the Preface section.

Tighten
11 N·m (97 lb in)

7

Transfer Case Bracket

8

Transfer Case Bracket Bolts (Qty: 2)

Tip
Tighten the bracket bolts to light assembly torque. Tighten to specification after the transfer case is mounted in the vehicle. Refer to Fastener Tightening Specifications.

1

Front Wheel Drive Intermediate Shaft

2

Front Wheel Drive Intermediate Shaft Bearing Retainers (Qty: 2)

3

Front Wheel Drive Intermediate Shaft Bearing Assembly

Tip
Use a press, with the J-22912-B Rear Pinion and Axle Bearing Remover flat side up, in order to install the bearing assembly.

Special Tools

J-22912-B Rear Pinion and Axle Bearing Remover

4

O-Ring

5

Half Shaft Retainer

1

Transfer Case Rear Output Shaft

2

Transfer Case Rear Output Shaft Bearing Spacer

3

Transfer Case Rear Output Shaft Housing

4

Transfer Case Rear Output Shaft Bearing Assembly

Tip
Use a press with the J-5590 Pinion Bearing Race Installer - Rear to install the housing and bearings to the output shaft.

Special Tools

J-5590 Pinion Bearing Race Installer - Rear

5

Transfer Case Rear Output Shaft Seal

Tip
Use a press with the DT-48075 Output Shaft Seal Installer to install the seal.

Special Tools

DT-48075 Output Shaft Seal Installer

1

Transfer Case Rear Output Shaft Oil Slinger

Tip
Use a press with the DT-48077 Output Shaft Slinger Installer in order to install the slinger.

Special Tools

DT-48077 Output Shaft Slinger Installer

2

Transfer Case Rear Output Shaft Flange

Tip
Use a press with the J-5590 Pinion Bearing Race Installer - Rear to install the flange.

Special Tools

J-5590 Pinion Bearing Race Installer - Rear

3

Transfer Case Rear Output Shaft Nut

Caution: Refer to Fastener Caution in the Preface section.

Tip
Use a 30 mm socket or the J-29873 Injector Nozzle Socket 30 mm and the J-08614-A Pinion Flange Holder and Remover .

Tighten
235 N·m (173 lb ft)

Special Tools

1

Transfer Case Half Locating Pins

2

Transfer Case Rear Output Drive Shaft

3

Transfer Case Input Shaft

Tip
Install the input and output shafts as a set with the splines engaged.

4

Transfer Case Seal

5

Transfer Case - Right

6

Transfer Case Half Bolts (Qty: 12)

Caution: Refer to Fastener Caution in the Preface section.

Tighten
29 N·m (21 lb ft)

1

Transfer Case Rear Output Shaft Housing Seal O-Ring

2

Transfer Case Rear Output Shim

3

Transfer Case Rear Output Shaft Housing

Caution: Do not use a drive hammer when the splines are not engaged. Use of a drive hammer when the splines are not engaged will damage the output shaft teeth.

Tip

Special Tools

J-25070 Heat Gun - 500-750F

4

Transfer Case Rear Output Shaft Housing Bolts (Qty: 6)

Caution: Refer to Fastener Caution in the Preface section.

Tighten
29 N·m (21 lb ft)

1

Front Wheel Drive Intermediate Shaft

Caution: DT-48094 must be used over the intermediate shaft prior to installation in order to protect the intermediate shaft seal from damage.

Special Tools

2

Front Wheel Drive Retainer

1

Transfer Case O-Ring Seal

2

Transfer Case Vent Assembly

Tip
Replace the vent if damaged or blocked.

3

Drain Plug

Caution: Refer to Component Fastener Tightening Caution in the Preface section.

Tighten
39 N·m (29 lb ft)

4

Fill Plug

Tighten
39 N·m (29 lb ft)

5

Transfer Case Heat Shield

6

Transfer Case Heat Shield Bolts (Qty: 3)

Caution: Refer to Fastener Caution in the Preface section.

Tighten
11 N·m (97 lb in)

7

Transfer Case Bracket

8

Transfer Case Bracket Bolts (Qty: 2)

Tip
Tighten the bracket bolts to light assembly torque. Tighten to specification after the transfer case is mounted in the vehicle. Refer to Fastener Tightening Specifications.