For 1990-2009 cars

#### Tools Required

J 36850 Transjel® Transmission Assembly Lubricant

1. Install the input shaft (3) with the input shaft needle bearing (2) onto the main shaft (1).
2. Install the main shaft (3) and the input shaft assembly (1) into the lower case (2).
3. Move all of the gearshift shafts to their neutral position.
4. Inspect the main shaft and the countershaft components for smooth engagement and rotation.

If the main shaft and countershaft fail to rotate smoothly, remove the main shaft from the lower case and inspect the countershaft for binding.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Apply Loctite™ 599 RTV silicone sealer or equivalent to the upper case mating surface (3).
6. Connect the upper case (1) to the lower case (2).

Secure the cases with the ten bolts.

Tighten
Tighten the upper-to-lower case retaining bolts to 23 N·m (17 lb ft).

7. Connect the input shaft bearing retainer (1) to the upper and lower case.

Secure the input shaft bearing retainer with the eight bolts (2, 3).

Tighten
Tighten the input shaft bearing retainer bolts to 23 N·m (17 lb ft).

8. Apply Loctite™ 599 RTV sealer or equivalent to the rear case mating surface (3).
9. Install the rear case (1) to the rear of the upper and lower case.

Secure the rear case with the 12 bolts.

Tighten
Tighten the rear case bolts to 23 N·m (17 lb ft).

10. Apply Loctite™ 599 RTV silicone sealer or equivalent to the gearshift lever case mating surface.
11. Install the transfer case to the rear case using a bolt.

Tighten
Tighten the bolt to 28 N·m (21 ft lb).

12. Connect the gearshift lever case to the rear cases.

Secure the gearshift lever case with the 10 bolts.

Tighten
Tighten the gearshift lever case bolts to 17 N·m (13 lb ft).

13. Connect the clutch housing to the upper and lower case.

Secure the clutch housing with 8 bolts (1,2).

Tighten
Tighten the clutch housing bolts to 45 N·m (33 lb ft).

14. Connect the clutch release bearing (2) and the clutch fork boot (1) to the input shaft.