Transfer Case Disassemble

Transfer Case Disassemble

Oil Drain Plug Removal





Remove and DISCARD the transfer case oil drain plug (1) and seal.

Fill Plug Removal





Remove and DISCARD the transfer case oil fill plug (1) and seal.

Transfer Case Vent Removal




1. Remove vent pipe bolt (1), if applicable.
2. Remove transfer case vent pipe (2) and vent pipe seal (3), if applicable.

Transfer Case Seal Removal





Remove the transfer case-to-transmission O-ring seal (1).

Locating Bushing Removal





Remove the transfer case locating bushing (1) as required using multigrip pliers.

Front Wheel Drive Intermediate Shaft Removal

Special Tools
* DT-113-A - Bracket
* DT-622-A - Adapter

For equivalent regional tools, refer to Special Tools (Graziano-F46 - Transfer Case).




1. Secure the transfer case (3) in DT-113-A - bracket (1), using the DT-622-A - adapter (2).




2. Remove the transfer case intermediate shaft retaining ring (1).




3. Remove the transfer case intermediate shaft (1), using a rubber mallet.

Front Wheel Drive Intermediate Shaft Bearing Removal

Special Tools

DT-307-B - Remover Plate

For equivalent regional tools, refer to Special Tools (Graziano-F46 - Transfer Case).




1. Remove the two transfer case intermediate gear bearing retaining rings (1, 2).




2. Remove the transfer case intermediate shaft bearing (1), using the DT-307-B - remover plate (2) and a hydraulic press.

Rear Output Shaft Seal Dirt Deflector Removal





Remove the rear output shaft seal dirt deflector (1), using a screw driver.

Rear Output Shaft Seal Removal




1. Install a sheet metal type screw (2) into the face of the rear output seal.
2. Remove the rear output shaft seal (1) with multigrip pliers.

Rear Output Shaft Housing Seal Removal




1. Remove the 7 transfer case rear output shaft housing bolts (1).
2. Remove the transfer case rear output shaft housing (2).
3. Remove the transfer case rear output shaft housing seal (3).
4. Clean all of the sealing surfaces.

Front Wheel Drive Input Shaft Removal




1. Remove the transfer case rear extension housing bolts (1) and rear extension housing (2).




2. Remove the rear extension housing (2) from the transfer case housing (1).




3. Remove the front wheel drive input shaft (1).
4. Remove the intermediate shaft seal (2) from the input shaft.

Idler Shaft Removal





Remove the idler shaft (1) from the housing.

Input Shaft Seal Removal




1. Remove the transfer case input shaft rear seal (1) using a suitable screw driver.




2. Remove the transfer case input shaft front seal (1) using a suitable screw driver.





Note: To avoid damage to the housing, use a brass punch to remove the seal.

3. Remove the transfer case input shaft seal (1) from the rear extension housing.

Rear Extension Locating Pin Removal





Remove the transfer case-to-rear extension housing locating pins (1) as required using multigrip pliers.