Steps 1 - 40

Transfer Case Disassemble

^ Tools Required
- J 23907 Slide Hammer with Bearing Adapter
- J 26941 Bushing and Bearing Remover (3-4 inch)
- J 36513 Gear and Bearing Separator Plate
- J 44707 T Bar Push Puller
- J 44737 Shift Rail Bearing Remover
- J 44759 Adapter 3/8 NC to 5/8 NF
- J 45358 Case Spreader

1. Remove the drain plug.
2. Tip the transfer case to remove any remaining transfer case fluid.

Notice: Refer to Transfer Case Seal Removal Notice in Service Precautions.

3. Using a fine flat-bladed screwdriver and a mallet, loosen the front input shaft seal.

4. Using a small block of wood and a large flat-bladed screwdriver, remove the front input shaft seal from the transfer case.

5. Remove the front input shaft seal.

6. Remove the dust seal from the front output shaft. The front output shaft oil seal does not require removal at this time.

7. Remove the transfer case bolt retaining the wiring harness bracket.
8. Mark the location of the wiring harness bracket bolt.
9. Remove the encoder/motor mounting bolts.

10. Remove the encoder/motor assembly.

Important: Remove the rear extension and case half bolts at the same time for easier rear case disassembly.

11. Remove the rear extension mounting bolts.

12. Remove the case half bolts.

Notice: Refer to Machined Surface Damage Notice in Service Precautions.

13. Install the J 45358 between the tabs on one side of the case.

Important:
^ Ensure that all of the case half bolts have been removed.
^ DO NOT use screwdrivers or pry bars to separate the transfer case halves. The special tool must be used to separate the transfer case halves properly.

14. Using the J 45358, shear the sealer securing the front and rear case half together.
15. Move the J 45358 to the tabs on the other side of the case and shear the sealer.

16. Use a suitable prying tool at one side of the case half.

17. Use a suitable prying tool at the other side of the cased halves.
18. Working both tools, separate the front input shaft from the front output shaft bearing, and the input shaft from the output shaft.

19. Remove the front case half from the rear case half. Only the input gear assembly will remain with the front case half.

Important: If reusing the drive chain and sprockets, mark the position of the drive chain to the sprockets in order for the proper wear pattern alignment.

20. Remove the front output shaft from the front output shaft rear bearing.
21. Remove the drive chain assembly from the drive gear on the output shaft and the driven gear on the front output shaft.

22. Remove the retaining ring for the high/low shift fork.

23. Remove the top shift fork spring.

24. Remove the shift fork assembly from the shift fork shaft.

25. Separate the shift fork from the range sleeve.

26. Remove the bottom shift fork spring.

27. Insert a screw driver in the slot of the rear extension.

28. Remove the rear extension from the rear case half.

29. Using the J 44707 (1), the J 44759 (2), and the J 36513 (3), remove the speed sensor reluctor wheel from the rear output shaft.
30. Discard the speed sensor reluctor wheel after removal.