Disassembly

DISASSEMBLY




1. Place the transfer case so that it can be drained of any remaining fluid and remove the drain plug (5).




2. Install Holder 6958 (1) onto the rear output flange (2).
3. Remove the output shaft nut.




4. Remove the rear output shaft flange (2) from the output shaft. If the flange is difficult to remove, use a suitable 2 or 3 jaw puller to remove the flange.




5. Install Holder 6958 (1) onto the front output flange (2).
6. Remove the output shaft nut.




7. Remove the front output shaft flange (2) from the output shaft. If the flange (2) is difficult to remove, use a suitable 2 or 3 jaw puller (1) to remove the flange.




8. Remove the bolts (3) holding the transfer case rear cover (2) to the transfer case.




9. Remove the transfer case cover (1) from the transfer case (2).




10. Remove the rear output shaft seal from the transfer case cover with a suitable pry tool.
11. Remove the rear output shaft bearing snap-ring (1) from the transfer case cover (2).
12. Remove the output shaft bearing from the cover using a suitable drift tool.




13. Remove the output shaft (1) from the planetary gear system (2).




14. Remove the snap-ring (2) holding the input shaft (1) to the planetary gear system (3).




15. Remove the planetary gear system (1) from the transfer case rear housing (2).




16. Remove the bolts (1) holding the rear housing (2) to the front housing.




17. Loosen the rear housing (1) from the front housing (2) by prying the sections apart at the provided slots. Remove the rear housing (1) from the front housing (2).




18. Remove the front output shaft (1) from the front housing (2).




19. Remove the intermediate gear (1) from the front housing (2).




20. Remove the input gear and hollow shaft assembly (1) from the front housing (2).




21. Remove the snap-ring (2) holding the input shaft (1) in the hollow shaft (3).




22. Remove the input gear thrust washer (2) from the input shaft (1) and hollow shaft (3).




23. Remove the hollow shaft (2) from the input shaft (1).

CAUTION: Inspect the needle bearing located inside the hollow shaft. If the needle bearing is within 1 mm (0.040 in.) of the edge of the hollow shaft, the hollow shaft must be replaced. DO NOT attempt to drive the bearing back into the hollow shaft.




24. Install the jaws from Remover L-4518 (2) into the intermediate gear rear bearing race in the rear housing (1).




25. Install the cup from Remover L-4518 (2) onto the jaws. Install the bearing, washer, and nut onto the threaded shaft and remove the bearing race.
26. Repeat STEP 24 and STEP 25 for the other blind bearing races in the front and rear housings.
27. Drive out the input gear and front output shaft seals with a suitable drift.
28. Drive out the front hollow shaft and front output shaft front bearing races with a suitable brass drift.




29. Remove the front output shaft (2) front bearing with Press C-293-PA (1) and Adapters C-293-52 (3).




30. Remove the front output shaft (4) rear bearing with Press C-293-PA (1), Plug 8513A (2), and Adapters C-293-52 (3).




31. Remove the front hollow shaft (3) bearing with Press C-293-PA (1), Plug 9678 (2), and Adapters C-293-48 (4).




32. Remove the rear hollow shaft (4) bearing with Press C-293-PA (1), Plug SP3289 (2), and Adapters C-293-48 (3).




33. Remove the front and rear intermediate gear (4) bearings with Press C-293-PA (1), Plug 8513A (2), and Adapters C-293-40 (3).