MP2010 Transfer Case - Disassembly

DISASSEMBLY

Special Tools:






1. Place the transfer case in a shallow pan and remove the fill and drain plugs to drain the remainder of the fluid.




2. Remove all the case bolts (1).
3. Using a prybar at notches (2, 3), carefully separate the case halves.





4. While lifting evenly, remove the chain (1) and sprockets (2, 3) from the input shaft and front output shaft.





5. Remove the snap ring (1) and the thrust washer (2) from the input shaft (3).





6. Remove the input shaft snap ring (1) from the input shaft (2).





7. Properly support the case half with input shaft off the work bench.
8. Using a plastic hammer (1), gently tap the input shaft (2) and remove from case half (3).





9. Remove the snap ring (1).
10. Using seal remover and slide hammer , remove input shaft seal (2) and discard.





11. Reinstall the input shaft into bearing and using a plastic hammer (1) gently tap on the input shaft (2) to remove input shaft bearing from the case half (3).






NOTE: There is a small snap ring on the shaft that sits in a grove in the bearing. To remove the shaft, it requires the snap ring be squeezed all the way around. A simple way of squeezing the snap ring is to use a small paper clip and work it in between the snap ring and the grove in the bearing all the way around. Once squeezed, lightly tap on the shaft to remove.

12. Remove the front output shaft from the transfer case.




13. Remove the differential (1) and oil slinger (2).
14. Remove the rear output shaft in the same manner as the front output shaft.





15. Using seal remover and slide hammer , remove the front and rear output shaft seals and discard. (Rear output seal shown, front similar.)





16. Using bearing race remover and slide hammer , remove the front and rear output shaft bearings and the support bearing in the rear case half. (Front output support bearing shown, all others similar.)