Chrysler 300/300 Touring/300C, Dodge Magnum. Manual — part 2086
18. Install the intermediate gear (1) into the front
housing (2).
19. Install the front output shaft (1) into the front
housing (2).
20. Clean the mating surfaces of the transfer case
housings.
21. Apply a 2 mm (0.08 in.) bead of MOPAR
T
Gasket
Maker around the perimeter of the front housing.
22. Set the rear housing (1) onto the front housing
(2).
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23. Install the bolts (1) to hold the rear housing (2) to
the front housing. Tighten the bolts in a cross pat-
tern to 34 N·m (25 ft.lbs.) for the 30 and 45 mm
long bolts.
24. Using locally acquired nuts, install the 120 mm
long bolts through the transfer case and install the
nuts to the bolts. Tighten the nuts to 10 N·m (7.5
ft.lbs.). Leave the 120 mm bolts torqued this way
for a minimum of 30 minutes to ensure that the
sealant has cured properly. After the 30 minutes,
the 120 mm bolts can be removed.
25. Install the planetary gear system (1) into the
transfer case rear housing (2).
26. Install the snap-ring (2) to hold the input shaft (1)
to the planetary gear system (3).
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27. Install the output shaft (1) into the planetary gear
system (2).
28. Install the output shaft bearing into the cover
using a suitable drift tool.
29. Install the rear output shaft bearing snap-ring (1)
into the transfer case cover (2).
30. Clean the mating surfaces of the transfer case
cover and the rear housing.
31. Apply a 2 mm (0.08 in.) bead of MOPAR
T
Gasket
Maker around the perimeter of the rear housing.
32. Position the transfer case cover (1) onto the
transfer case (2).
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33. Install the bolts (3) to hold the transfer case rear
cover (2) to the transfer case. Tighten the bolts in
a cross pattern to 34 N·m (25 ft.lbs).
34. Install the rear output shaft seal from the transfer
case cover (2) with Installer C-3860A (1).
NOTE: For the most accurate torque reading,
apply a light coating of oil to the nut face that con-
tacts the flange and to the flange splines.
35. Install the rear output shaft flange (2) onto the
output shaft. Install a new nut.
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