Disassembly

Fig. 17 Rear Case Half. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 18 Front Case Half. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 19 Transfer Case Exploded View. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 20 Oil Pump, Pickup Tube & Screen. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 21 Mode Fork & Shaft Assembly. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 22 Shift Rail Assembly. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 23 Input Gear Bearing Removal. New Process Models 231, 233 & 241 Transfer Cases:

Fig. 24 Front Output Shaft Rear Bearing Removal. New Process Models 231, 233 & 241 Transfer Cases:

1. Remove front output yoke (Models 231 and 233) or flange (Model 241) nut, washer, rubber sealing washer from front output shaft. Refer to Figs. 17 through 24 during disassembly of transfer case.
2. Remove indicator lamp switch and O-ring seal.
3. Remove poppet screw, O-ring seal, poppet spring and poppet plunger.
4. Remove rear extension housing bolts and rear extension.
5. Remove bearing retainer (snap ring) from mainshaft.
6. Remove pump retainer housing bolts, then pump retainer housing from rear case half.
7. Remove speedometer drive gear (Models 231 and 233) or speedometer tone wheel (Model 241) from mainshaft.
8. Remove case bolts from case halves. The two longer case bolts go into doweled case holes. Separate case halves by prying halves apart at slots cast in case ends. Do not wedge halves apart at any point on mating surface. Ensure that oil pump is not damaged when rear case half is removed.
9. Remove oil pump, pickup tube, O-ring and filter from rear case half.
10. Remove fork shift spring. At this time, remove retainer (snap ring) from front output shaft on model 241.
11. Remove mainshaft, chain and driven sprocket as a unit from front case half. Mode shift fork and shift rail will be removed with mainshaft.
12. Remove retainer (snap ring) from mainshaft.
13. Remove synchronizer assembly, then drive sprocket from mainshaft.

Fig. 19 Transfer Case Exploded View. New Process Models 231, 233 & 241 Transfer Cases:

14. Remove range shift fork and range shift hub and sector with shaft from planetary carrier. It is necessary to rotate sector with shaft to provide clearance when removing fork (51), Fig. 19.
15. Remove shift lever nut, washer, shift lever, plastic washer and O-ring seal from front case half, then remove bearing retainer (snap ring).
16. Remove planetary carrier and input gear from annulus gear using soft faced hammer.
17. On models 231 and 233, remove input bearing from front case half using J-36370 and J-8092. On model 241, remove retainer ring (snap ring) from input gear, then remove input bearing from input gear using J-22912-1.
18. Remove drive sprocket bearings from drive sprocket. On models 231 and 233, use J-29170 and J-8092. On model 241, use J-29369-1 and J-2619-01.
19. Remove needle bearings from input gear using J-29369-1 (J-29369-2 for model 241). J-9276-21 and J-2619-01.
20. On models 231 and 233, remove front output shaft seal from front case half. On model 241, Remove front output bearing retainer snap ring.
21. On models 231 and 233, remove front output bearing retainer snap ring. On model 241, remove front output shaft seal from front case half.
22. Remove front output bearing from front case half using J-33790 on model 231 and 233, J-33832 on model 241 and J-8092 on both models.
23. remove seal from mainshaft extension housing and seal from input bearing retainer.
24. Remove front output rear bearing from rear case half using J-2619-01 and J-29369-2 on models 231 and 233. On model 241, insert J-29369-2 behind needle bearings and using J-2619-5, hammer the bearing from case.
25. Remove mainshaft bearing from oil pump retainer using J-33790.
26. Remove magnets from front case half.
27. Mark location of synchronizer hub and sleeve for reference during assembly.
28. Remove main drive synchronizer stop ring from synchronizer sleeve.
29. Remove spring retainer from synchronizer sleeve, then remove synchronizer hub from the synchronizer.
30. Remove oil pump screw from oil pump, then remove inner gear.