For 1990-2009 cars

#### Tools Required

• | J 8092 Driver Handle

• | J 36370 Drive Sprocket Needle Bearing Installer

• | J 36371 Front And Rear Output Shaft Bearing Installer

• | J 36372 Input Gear Needle Bearing Installer

• | J 36373 Input Gear Bearing Installer

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.

1. Install the following components to the front case half:

1.1. | The detent plunger

1.2. | The detent spring

1.3. | The O-ring seal

1.4. | The detent plug

Tighten
Tighten the detent plug to 15 N·m (11 lb ft).

2. Install the vehicle speed sensor and the O-ring to the rear retainer housing.

Tighten
Tighten the vehicle speed sensor to 31 N·m (23 lb ft).

3. Install the four wheel drive actuator switch and the O-ring to the front case half.

Tighten
Tighten the actuator switch to 24 N·m (17 lb ft).

4. Install the following components:

4.1. | The front output flange

4.2. | The rubber sealing washer

4.3. | The washer

4.4. | The nut

Tighten
Tighten the yoke nut to 200 N·m (148 lb ft).

Important: Use Dexron® III automatic transmission fluid or equivalent when needed in assembly.

Important: The bearing must be flush with the boss on the case housing.

5. Use the J 36372 and the J 8092 to install the needle bearing into the rear case.
6. Use the J 36371 to install the front output bearing into the front case.
7. Install the front output bearing snap ring into the front case half.
8. Use the J 36371 to install the bearing into the rear retainer housing.
9. Use the J 8092 and the J 36372

to install the mainshaft pilot bearing into the input gear.

10. Install the thrust washer into the planetary carrier.
11. Install the input gear to the planetary carrier snap ring.
12. Use the J 36373 to install the bearing into the input gear.
13. Install the input bearing to the input gear snap ring.
14. Install the oil seal to the rear extension.
15. Install the input bearing retainer seal to the input bearing retainer.
16. Install the front output shaft seal to the front case half.
17. Install the magnet to the front case half.