Disassembly

DISASSEMBLY





Position transfer case on shallow drain pan. Remove drain plug (3) and drain lubricant remaining in case.


SHIFT MOTOR ASSEMBLY





1. Remove the bolts (2) which hold the shift motor and mode sensor assembly (1) to the transfer case.




2. Remove the shift motor and mode sensor assembly (1) from the transfer case.




3. Remove and discard the shift motor O-ring (2) from the shift motor (1).




4. Remove the transfer case shift screw (1) and top bearing from the transfer case.




5. Remove the shift screw lower bearing (1) from the transfer case.

REAR CASE





1. Support transfer case so rear case is facing upward.
2. Remove bolts holding the front case (2) to the rear case (1).
3. Loosen rear case with flat blade screwdriver to break sealer bead.
4. Remove the rear case (1) from the front case (2).

DRIVE CHAIN AND SPROCKETS





1. Remove the shift fork (1) and sleeve (2) as an assembly.




2. Remove the front output shaft drive sprocket (1) retaining ring (2).




3. Remove the mainshaft drive sprocket (1) retaining ring (2).




4. Remove the front output shaft drive sprocket (1), the mainshaft drive sprocket (3), and the drive chain (2) as one unit.

FRONT OUTPUT SHAFT





1. Remove the front propeller shaft seal boot (1) retaining clamp (2).




2. Remove the front propeller shaft seal boot (2) from the front output shaft seal slinger (3).




3. Using a suitable hammer and chisel, strike the seal slinger (2) with the chisel as shown in three, equally spaced locations.




4. The indentations (2) should appear as shown here.




5. Remove the front output shaft seal slinger (1) from the output shaft (2).




6. Remove the front output shaft seal (1) from the transfer case bore (2) using a suitable tool.




7. Remove the front output shaft retaining ring (2) from the output shaft (1).




8. Remove the front output shaft (1) from the transfer case front case.

MAINSHAFT





1. Remove the mainshaft assembly (1) from the input gear (2).




2. Remove the mainshaft thrust washer (1) from the input gear (2).




3. Remove the differential retaining ring (1) from the mainshaft.




4. Remove the differential assembly (1) from the mainshaft (2).

DIFFERENTIAL





1. Remove the mode hub and mode hub retainer (2) from the differential assembly (1).




2. Remove the mode hub retainer (1) from the mode hub (2).

INPUT GEAR





1. Remove the input gear assembly (2) retaining ring (1) from the transfer case.




2. Remove the input gear assembly (1) from the transfer case front case.