Disassembly

NV233 - Transfer Case
DISASSEMBLY
Position transfer case on shallow drain pan. Remove drain plug and drain lubricant remaining in case.


REAR RETAINER AND OIL PUMP
1. Remove extension housing bolts.






2. Tap extension housing with plastic or rawhide mallet to loosen sealer (Fig. 3).
3. Separate extension housing from rear retainer.






4. Remove rear bearing snap-ring (Fig. 4).
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. 5).






7. Disengage oil pickup tube from oil pump and remove oil pump assembly (Fig. 6).






8. Remove pick-up tube O-ring from oil pump (Fig. 7), if necessary. Do not disassemble the oil pump, it is not serviceable.




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. 8) 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.



FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Support transfer case so rear case is facing upward.






2. Remove bolts holding front case to rear case. The case alignment bolts require flat washers (Fig. 9)






3. Loosen rear case with flat blade screwdriver to break sealer bead. Insert pry tool blade only into notches provided at each end of case (Fig. 10).
4. Remove rear case from front case.






5. Remove oil pickup tube from rear case (Fig. 11).






6. Remove mode fork spring (Fig. 12).






7. Pull front output shaft upward and out of front output shaft bearing (Fig. 13).
8. Remove front output shaft and chain.







SHIFT FORKS AND MAINSHAFT
1. Remove detent plug, O-ring, detent spring and detent plunger (Fig. 14).
2. Remove mainshaft from mode sleeve and input gear pilot bearing.






3. Remove mode fork and sleeve as an assembly (Fig. 15). Note position of sleeve for assembly reference. The short side of the sleeve faces upward.






4. Remove range fork and hub as an assembly (Fig. 16). Note fork position for installation reference.






5. Remove shift sector from front case (Fig. 17).






6. Remove shift sector O-ring (Fig. 18).







MAINSHAFT
1. Remove mode hub retaining ring with heavy duty snap-ring pliers (Fig. 19).






2. Slide mode hub off mainshaft (Fig. 20).






3. Slide drive sprocket off mainshaft (Fig. 21).







INPUT GEAR AND LOW RANGE GEAR
1. Remove front bearing retainer attaching bolts (Fig. 22).






2. Remove front bearing retainer. Pry retainer loose with pry tool positioned in slots at each end of retainer (Fig. 23).
3. Remove front bearing retainer seal. Tap seal out with drift and hammer.






4. Remove input gear retaining ring with heavy duty snap-ring pliers (Fig. 24)






5. Place front case in horizontal position. Then remove input gear and low range gear as an assembly (Fig. 25). Tap gear out of bearing with plastic mallet if necessary.







INPUT AND LOW RANGE GEAR
1. Remove snap-ring that retains input gear in low range gear (Fig. 26).






2. Remove retainer (Fig. 27).






3. Remove front tabbed thrust washer (Fig. 28).






4. Remove input gear (Fig. 29).






5. Remove rear tabbed thrust washer from low range gear (Fig. 30).