For 1990-2009 cars

Table 1: | Intermediate Drive Shaft Assembly
Table 2: | Rear Output Shaft Housing Assembly
Table 3: | Output Flange Installation
Table 4: | Right Transfer Case, Input Shaft, and Output Drive Shaft Installation
Table 5: | Rear Output Shaft Housing Installation
Table 6: | Intermediate Drive Shaft Installation
Table 7: | Housing O-Ring, Vent Assembly, Drain and Fill Plug Installation

### Intermediate Drive Shaft Assembly

Callout | Component Name
--- | ---
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

### Rear Output Shaft Housing Assembly

Callout | Component Name
--- | ---
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

### Output Flange Installation

Callout | Component Name
--- | ---
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

• | J-08614-A Pinion Flange Holder and Remover

• | J-29873 Injector Nozzle Socket 30 mm

### Right Transfer Case, Input Shaft, and Output Drive Shaft Installation

Callout | Component Name
--- | ---
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)

### Rear Output Shaft Housing Installation

Callout | Component Name
--- | ---
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

• | Use of a heat gun allows easy alignment of the bolt holes to the housing during assembly.

• | Rotate the pinion gear during assembly to engage the gear teeth.

#### 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)

### Intermediate Drive Shaft Installation

Callout | Component Name
--- | ---
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

• | DT-48094 Inner Drive Shaft Seal Protector

• | J-25070 Heat Gun - 500-750F

2 | Front Wheel Drive Retainer

### Housing O-Ring, Vent Assembly, Drain and Fill Plug Installation

Callout | Component Name
--- | ---
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.