Disassembly
NV244 - Transfer Case
DISASSEMBLY
COMPANION FLANGE AND SHIFT MOTOR ASSEMBLY
1. Remove front companion flange nut with a socket and impact wrench
2. Remove the front companion flange. If the flange is difficult to remove by hand, remove it with bearing splitter, or with standard two jaw puller. Be sure puller tool is positioned on the flange and not on the slinger, as slinger will be damaged.
3. Remove seal washer from front output shaft. Discard washer as it should not be reused.
4. Remove the bolts (Fig. 3) which hold the shift motor and mode sensor assembly to the transfer case.
5. Remove the shift motor and mode sensor assembly from the transfer case.
REAR RETAINER
1. Remove extension housing bolts.
2. Tap extension housing with plastic or rawhide mallet to loosen sealer (Fig. 4).
3. Separate extension housing from rear retainer.
4. Remove rear bearing snap-ring (Fig. 5).
5. Remove bolts holding rear retainer to rear case half.
6. Loosen rear retainer with pry tool to break sealer bead. Pry only against retainer boss as shown (Fig. 6).
7. Remove rear bearing O.D. retaining ring with snap-ring pliers. Then tilt pump and slide it off output shaft (Fig. 7)
8. Remove pickup tube O-ring from pump (Fig. 8) but do not disassemble pump; it is not a repairable part.
9. Remove seal from oil pump with pry tool.
10. Remove bolts attaching rear case to front case (Fig. 9). Note position of the two black finish bolts at each end of the case. These bolts go through the case dowels and require a washer under the bolt head.
11. Remove rear case from front case (Fig. 10). Insert screwdrivers into slots cast into each end of case. Then pry upward to break sealer bead and remove rear case.
CAUTION: Do not pry on the sealing surface of either case half as the surfaces will become damaged.
12. Remove oil pickup tube and screen from rear case (Fig. 11).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Remove drive sprocket snap-ring (Fig. 12).
2. Remove drive sprocket and chain (Fig. 13).
3. Remove front output shaft (Fig. 14).
SHIFT FORKS AND MAINSHAFT
1. Remove shift detent plug, spring and pin (Fig. 15).
2. Remove shift rail by pulling it straight up and out of fork (Fig. 16).
3. Remove mode fork and mainshaft as assembly (Fig. 17).
4. Remove mode shift sleeve and mode fork assembly from mainshaft (Fig. 18). Note position of mode sleeve in fork and remove sleeve.
5. Remove intermediate clutch shaft snap-ring (Fig. 19).
6. Remove clutch shaft thrust ring (Fig. 20).
7. Remove intermediate clutch shaft (Fig. 21).
8. Remove differential snap-ring (Fig. 22).
9. Remove differential (Fig. 23).
10. Remove differential needle bearings and both needle bearing thrust washers from mainshaft.
11. Slide low range fork pin out of shift sector slot (Fig. 24).
12. Remove low range fork and hub (Fig. 25).
13. Remove shift sector.
14. Remove shift sector O-ring (Fig. 26).
INPUT GEAR/LOW RANGE ASSEMBLY
1. Remove front bearing retainer bolts.
2. Remove front bearing retainer. Carefully pry retainer loose with screwdriver (Fig. 27). Position screwdriver in slots cast into retainer.
3. Remove input gear snap-ring (Fig. 28).
4. Remove input/low range gear assembly from bearing with Tool Handle C-4171 and Tool 7829-A (Fig. 29).
5. Remove low range gear snap-ring (Fig. 30).
6. Remove input gear retainer, thrust washers, and input gear from low range gear (Fig. 31).
7. Inspect low range annulus gear (Fig. 32). Gear is not a serviceable component. If damaged, replace gear and front case as an assembly.
8. Remove oil seals from the following components:
- front bearing retainer.
- rear retainer.
- oil pump.
- case halves.
DIFFERENTIAL
1. Mark differential case halves for reference.
2. Remove differential case bolts.
3. Invert differential on workbench.
4. Separate top case from bottom case. Use slots in case halves to pry them apart (Fig. 33).
5. Remove thrust washers and planet gears from case pins (Fig. 34).
6. Remove mainshaft and sprocket gears from bottom case (Fig. 35). Note gear position for reference before separating them.