Disassembly

DISASSEMBLY

Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining in case.


SHIFT MOTOR ASSEMBLY AND FRONT OUTPUT SHAFT SEAL





1. Remove the bolts (3) which hold the shift motor and mode sensor assembly (2) to the transfer case (1).




2. Remove the shift motor and mode sensor assembly from the transfer case.
3. Remove the front propeller shaft seal boot (1) retaining clamp (2).




4. Remove the front propeller shaft seal boot (1).




5. Remove the front output shaft seal slinger (1) by bending (2) the slinger ears away from the transfer case.




6. Using a suitable pry tool (2), remove the slinger (1) from the output shaft using care not to damage the shaft.
7. Using a screw and a slide hammer, remove the front output shaft seal.

REAR EXTENSION





1. Remove rear extension bolts (1).




2. Remove rear extension housing (1). Tap extension once or twice with a plastic mallet to break sealer bead and loosen it.




3. Remove output bearing (2) retaining ring (3) with heavy duty snap-ring pliers.

OIL PUMP AND REAR CASE





1. Remove rear case (1)-to-front case (2) bolts (3).




2. Loosen rear case (1) with pry tool to break sealer bead. Insert tool in slot (3) at each end of case.




3. Unseat rear case from alignment dowels.
4. Remove rear case (1) and oil pump assembly from front case (2).

CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft inner bearing race and will become mis-aligned if the bolts are loosened. If the transfer case failure has generated any debris which may have become trapped in the oil pump. the rear case and oil pump assembly MUST be replaced.

5. Remove the oil pump pickup tube.

FRONT OUTPUT SHAFT AND DRIVE CHAIN





1. Remove shift rail cup (3) and spring (2).




2. Remove front sprocket (1) retaining ring (2).




3. Pull mainshaft (3), front sprocket (1), and chain (2) outward about 25 mm (1 inch) simultaneously.
4. Remove chain from mainshaft drive sprocket and remove front sprocket and chain as assembly.

SHIFT FORKS AND MAINSHAFT





1. Loosen detent plug (2).
2. Remove detent plug (2), spring (3), and plunger (4). Note that the plug has an O-ring seal. Remove and discard this seal.




3. Remove the front output shaft (1) snap-ring (2).




4. Remove front output shaft (2) from bearing in the front case (1).




5. Pull mainshaft assembly (2) out of input gear, mode sleeve, and front case (1).




6. Remove mode fork (2), mode sleeve (1), and shift rail as assembly. Note which way the sleeve fits in the fork (long side of sleeve goes to front).




7. Remove range fork retaining ring.
8. Remove range fork (2) and hub (1) as an assembly. Note fork position for installation reference.




9. Remove shift sector (1).




10. Remove the shift sector O-ring (2) from the front housing (1).

MAINSHAFT





1. Remove the drive sprocket (3) retaining ring (2) from the output shaft (1).




2. Remove the drive sprocket (3) thrust washer (2) from the output shaft (1).




3. Remove drive sprocket (2) from the output shaft (1).




4. Remove the clutch gear (2) from the output shaft (1).




5. Remove the sprocket hub (2) from the output shaft (1).




6. Remove the mode hub retaining ring (2) from the output shaft (1).




7. Remove the mode hub (2) from the output shaft (1).

INPUT AND PLANETARY GEAR





1. Remove input gear seal with suitable screw and slide hammer.
2. Remove input gear (1) retaining ring (2) with heavy duty snap-ring pliers.




3. Place front case in horizontal position. Then remove input gear and low range gear as an assembly (2). Tap gear out of bearing with plastic mallet, if necessary.

INPUT AND PLANETARY GEAR





1. Remove snap-ring (1) that retains input gear in low range gear.




2. Remove retainer (3).




3. Remove front tabbed thrust washer (1).




4. Remove input gear (1).




5. Remove rear tabbed thrust washer (2) from low range gear (1).