Steps 52 - 98
Transfer Case Disassemble^ Tools Required
- J 22912-01 Split Plate Bearing Puller
- J 23907 Slide Hammer with Bearing Adapter
- J 26941 Bushing and Bearing Remover - 3-4 inch
- J 45380 Transfer Case Rear Bushing Remover and Installer
1. Remove the fiji plug (1) and the drain plug (2) and drain the transfer case fluid.
2. Remove the connector, for the actuator encoder motor wiring harness, from the bracket.
3. Remove the actuator encoder motor mounting bolts.
4. Remove the actuator encoder motor assembly.
5. Remove the actuator insulator gasket.
6. Remove the encoder motor mounting bolts.
7. Remove the encoder motor assembly.
8. Remove the actuator insulator gasket.
9. Remove the vent and the seal, if damaged.
10. Remove the rear Vehicle Speed Sensors (VSS).
11. Remove the front VSS.
12. Remove the access hole plug.
Notice: Refer to Transfer Case Seal Removal Notice in Service Precautions.
13. Remove the input shaft seal by prying it out of the front case.
14. Remove the rear output shaft seal.
15. Inspect the rear output shaft bushing for scoring or wear.
16. Remove the rear output shaft bushing using the J 45380.
^ Install the finger section of the J45380 in front of the bushing.
^ Install the tube and forcing screw assembly to the finger section. Ensure the forcing screw is backed out.
^ Using a wrench on the forcing screw, remove the rear output shaft bushing.
17. Remove the transfer case retaining bolts and washers. Mark the location of any brackets.
Notice: Refer to Machined Surface Damage Notice in Service Precautions.
18. Insert a flat-bladed screwdriver into the slot on the left side of the transfer case.
19. Insert a flat-bladed screwdriver into the slot on the right side of the transfer case.
20. With equal pressure, press down on the screwdrivers in order to separate the front case half and the rear case half.
21. Insert a pair of snap ring pliers and release the outer retaining ring for the rear output shaft bearing.
22. Remove the rear case half from the front case half.
23. Remove the oil pump wear sleeve, only if worn or damaged.
24. Remove the rear output shaft rear bearing retaining ring.
25. Remove the rear output shaft rear bearing.
26. Remove the rear output shaft speed sensor reluctor wheel.
27. Remove the magnet.
28. If 1ST design, disconnect the oil pump suction pipe from the oil pump screen.
29. If 1ST design, remove the oil pump screen from the front case half.
30. If 1ST design, remove the oil pump suction pipe from the oil pump inlet hole.
31. If 1ST design, remove the oil pump suction pipe O-ring from the oil pump.
32. If 2nd design, remove the oil pump suction pipe assembly. Do not remove the screen from the pipe.
33. Remove the oil pump wave spring.
34. Remove the oil pump assembly.
35. Remove the oil pump suction pipe 0-ring from the oil pump.
36. Remove the drive sprocket retaining ring.
37. Remove the driven sprocket retaining ring.
Important: If the chain and sprockets are to be reused, mark the relationship of the chain to the sprockets in order to mark the wear patterns.
38. Remove the chain from the drive sprocket and driven sprocket.
39. Remove the rear output shaft assembly.
40. Mount the rear output shaft assembly in a soft-jaw vise with the output end up.
41. Remove the clutch assembly retaining ring. Push down on the clutch pressure plate to access the retaining ring.
42. If 1st design, remove the clutch apply plate assembly
43. If 1st design, remove the clutch return spring.
44. If 2nd design, remove the clutch apply plate assembly.
45. If 2nd design, remove the clutch return spring.
46. If 1ST design, remove the clutch apply plate bearing, with the clutch bearing inner support from the clutch apply plate.
47. If necessary remove the retaining ring from the clutch apply plate.
48. If 2nd design, remove the clutch apply plate bearing and inner support from the clutch apply plate.
49. Inspect the bearing for being faulty.
50. If the bearing is faulty, using a hydraulic press and a suitable adapter, remove the clutch pressure plate bearing from the clutch pressure plate hub.
51. Discard the bearing after removal.
52. Remove the clutch hub retaining ring.
Important: Do not remove the oil restrictor plate on the 2nd design clutch hub. The oil restrictor plate is only serviced with the clutch hub.
53. If 1st design, remove the clutch hub oil restrictor plate.
54. Remove the clutch housing and hub assembly from the rear output shaft.
55. If 1st design, turn the clutch assembly over on a work bench.
56. If 1st design, remove the clutch housing.
57. If 1st design, remove the clutch hub.
58. If 1st design, remove the clutch backing plate.
59. If 2nd design, remove the clutch housing
60. If 2nd design, remove the clutch hub.
Important: Do not wash the clutch friction or inner pressure plates in cleaning solvent.
61. Separate the clutch plates for inspection.
62. Remove and discard the shim or shims.
63. Remove the oil restrictor from the rear output shaft, if replacing the shaft.
64. Inspect the bearing in the clutch housing for being faulty.
65. If the bearing is faulty, use a brass drift and a hammer to remove the bearing.
66. Remove both of the clutch lever pivot pins.
67. Remove the shift detent spring bolt.
68. Remove the following components:
^ The shift detent plunger plug O-ring seal
^ The shift detent spring
^ The shift detent plunger
69. Remove the clutch lever from the control actuator lever.
70. Remove the shift fork shaft.
71. Remove the range shift fork and the range shift sleeve as an assembly.
It may be necessary to pry the roller on the shift fork from the control actuator lever.
72. Remove the range shift sleeve from the range shift fork.
73. Remove the outer retaining ring for the input gear bearing.
Important: The transfer case may use either a 4 pinion or 6 pinion planetary carrier assembly with the 27 tooth input gear version of the transfer case, transmission RPO M30. If the 6 pinion planetary carrier assembly used with the 27 tooth input gear requires replacement, the service part will be a 4 pinion planetary carrier assembly. The 4 pinion and 6 pinion planetary carriers are interchangeable. The 32 tooth input gear transfer case version used with transmission RPO MT1 and RPO MN8 will still use the 6 pinion planetary carrier assembly.
74. Remove the high/low planetary carrier.
75. Remove the planetary gear shaft retaining ring.
76. Remove the input shaft thrust bearing washer.
77. Remove the input shaft thrust bearing.
78. Remove the input gear from the planetary carrier.
79. Remove the thrust washer.
80. Inspect the pilot bearing in the input gear for being faulty.
81. Remove the pilot bearing from the input gear using a brass drift and a hammer.
82. Remove the inner retaining ring for the front output shaft bearing.
83. Using a softface hammer, remove the front output shaft, with the bearing, from the front case halt.
84. Using a suitable punch, remove the front output shaft seal from the front case half.
85. Remove the outer retaining ring for the front output shaft bearing.
86. Inspect the front output shaft bearing for being faulty.
87. Remove the bearing from the front output shaft. Do not use the bearing again after removal.
88. If damaged, remove the speed sensor reluctor wheel from the front output shaft, using a hydraulic press. Do not use the speed sensor reluctor wheel again after removal.
89. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.
90. Remove the input bearing retaining ring.
91. Remove the input bearing.
92. Inspect the front output shaft rear bearing for being faulty.
93. If the bearing is faulty, remove the bearing using the J 23907 (2) and the J 26941 (1).
94. Remove the retaining ring for the control actuator lever shaft.
95. Remove the control actuator lever shaft.
96. Inspect the control actuator lever bearing and seal for being faulty.
97. If the bearing is leaking or faulty, remove the bearing from the case.
98. Remove the drain and fill plugs.