Transfer Case Disassemble

Transfer Case Disassemble

Oil Drain Plug Removal





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

Fill Plug Removal





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

Transfer Case Vent Removal





Remove the transfer case vent (1), as required.

Transfer Case-to-Transmission Seal Removal





Remove and discard the transfer case-to-transmission seal (1).

Locating Bushing Removal





Remove the transfer case locating bushing (1), using multi-grip pliers as required.

Front Wheel Drive Intermediate Shaft Removal

Special Tools
* DT-113-2-A - Holder
* DT-622-A - Transmission Bracket

For equivalent regional tools, refer to Special Tools (Tools and Equipment).




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




2. Install a sheet metal screw (2) into outer surface of seal and remove the shaft dirt deflector and grease seal assembly with suitable pliers.
3. DISCARD the shaft dirt deflector and grease seal assembly (1).




4. Remove the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.




5. Remove the transfer case intermediate shaft (1), with bearing, 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 (Tools and Equipment).




1. Remove the transfer case intermediate shaft bearing retaining ring (2) from intermediate shaft (1), using suitable pliers.




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

Rear Output Shaft Seal Removal





Note: Be sure to only pry against the five flat bosses on the rear output shaft housing.

1. Remove the inner metal sleeve (1) from the seal by working a screwdriver around the perimeter of the sleeve, prying only against the flat bosses of the output shaft housing.





Note:
* Be sure to only pry against the five flat bosses on the rear output shaft housing.
* The seal tension spring (2) may fall off as the seal is removed.

2. Remove the rear output shaft seal (1) by working a sharpened chisel around the perimeter of the seal, prying only against the flat bosses of the output shaft housing.
3. Ensure the seal tension spring (2) is removed from the bore.

Input Shaft Bearing Retainer Rear Seal Removal




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





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

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

Input Shaft Bearing Retainer Front Seal Removal




1. Remove idler gear shaft (1) from transfer case. - RPO MXE
2. Remove input shaft (3) and idler gear (2).





Note: There are two input shaft front seals located in the transfer case housing.

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





Note: There are two input shaft front seals located in the transfer case housing.

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

Rear Extension Locating Pin Removal





Remove the 2 transfer case rear extension housing locating pins (1), using multigrip pliers as required.

Idler Gear Shaft Rear Seal Removal





Remove the transfer case idler gear shaft rear seal (1) from the rear extension housing. - RPO MXE

Front Wheel Drive Intermediate Shaft Seal Removal





Remove the intermediate shaft seal (1) using a suitable screw driver.

Idler Gear Shaft Front Seal Removal





Remove the transfer case idler gear shaft front seal (1) from transfer case. - RPO MXE