1. Transfer Case Disassemble
Transfer Case Disassemble
^ Tools Required
- J 2619-01 Slide Hammer
- J 3289-20 Holding Fixture
- J 22912-01 Rear Pinion and Axle Bearing Remover
- J 23907 Slide Hammer with Bearing Adapter
- J 26941 Bushing and Bearing Remover - 3-4 inch
- J 45358 Case Spreader
- J 45548 Mainshaft Support Bushing/Bearing Remover
- J 45759 Assembly Fixture
1. Attach the J 45759 to the transfer case using the adapter studs. All of the transfer case disassembly procedures can be performed with the case mounted to the J 45759.
2. Mount the J 3289-20 (1) to a sturdy workbench.
3. Install the J 45759 (2) into J 3289-20 (1) and secure with pivot pin.
4. Remove the drain plug and the fill plug. Ensure all of the transfer case fluid is drained out of the transfer case.
5. Remove the front output shaft seal by inserting a flat-tip screwdriver behind the inner race of the seal.
Notice: Refer to Transfer Case Seal Removal Notice in Service Precautions.
Important: The front output shaft seal is a two piece internal seal. The inner seal race is a force fit on the front output shaft.
6. Pry the inner seal race forward.
7. Using a small pry bar, move the inner seal race forward on the front output shaft.
8. Remove the inner seal race from the front output shaft.
9. Insert a flat-tip screwdriver or a small pry bar between the outer lip of the front output shaft seal and the transfer case.
10. Remove the remaining part of the front output shaft seal from the transfer case.
11. Remove the vehicle speed sensor (VSS) and the O-ring seal.
12. Remove the rear output shaft seal by prying it out with a flat-blade screwdriver.
Notice: Refer to Transfer Case Seal Removal Notice in Service Precautions.
13. Remove the transfer case retaining bolts and washers. Mark the location of the brackets.
14. Using the J 45358 between the tabs on the case halves, shear the sealer that is holding the case halves together.
Notice: Refer to Machined Surface Damage Notice in Service Precautions.
15. Using pry bars at each side of the case, remove the case from the locating pins.
16. Remove the rear case half from the front case half. The rear output shaft will come with the rear case half.
17. Remove the rear sun gear.
18. Remove the sun gear thrust washer.
19. Remove the planetary differential assembly.
20. Remove the front sun gear.
21. Remove the chain with the drive sprocket and driven sprocket.
Important: If the chain and sprockets are to be used again, mark the relationship of the chain to the sprockets in order to mark the wear patterns.
22. Remove the input shaft.
23. Remove the front output shaft assembly.
24. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.
25. Using a hammer and a suitable punch, remove the input seal.
26. Using a hammer and a brass drift, remove the input shaft bearing from the front case half.
27. Using a brass drift, remove the front output shaft bearing from the front case half.
28. If necessary, remove the vent from the front case half.
29. Remove the rear output shaft from the rear case half.
1. Spread the rear output shaft rear bearing outer retaining ring.
2. Using a soft-face hammer, tap on the end of the rear output shaft.
30. Using a hydraulic press and the J 22912-01, remove the speed reluctor wheel. Do not use the speed reluctor wheel again.
31. Remove the retaining ring for the rear output shaft bearing.
32. Using a hydraulic press, remove the rear output shaft bearing.
33. Inspect the mainshaft rear support bushing in the rear output shaft for being faulty.
34. Using the J 2619-01 (1) and the J 45548 (2), remove the mainshaft rear support bushing from the rear output shaft.
35. Using the J 26941 (1) and the J 23907 (2), remove the rear bearing for the front output shaft from the rear case.