Part 1

DISASSEMBLY

Special Tools:






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

COMPANION FLANGE AND EXTENSION HOUSING










1. Install two bolts 180° apart into the front output shaft companion flange.
2. Place holder (1)(Figure 1) over the bolts (2) and against the companion flange.
3. Remove and discard the front companion flange nut.
4. Remove the companion flange from the front output shaft. It may be necessary to use Pinion Flange Remover to remove the companion flange.










5. Use a suitable chisel or pry tool to remove the rear extension housing (1) dust boot (2)(Figure 2).
6. Use a suitable chisel or pry tool to remove the rear extension housing seal.










7. Remove rear extension (1) bolts (2)(Figure 3).










8. Remove rear extension housing (2)(Figure 4) from the rear case half. Tap extension once or twice with a plastic mallet to break sealer bead and loosen it.

OIL PUMP AND REAR CASE










1. Disengage the oil pump pick-up tube (2)(Figure 5) from the oil pump (1).

NOTE: The oil pump pick-up tube seals to the oil pump with an o-ring. Verify that the o-ring was removed with the tube and is in good condition. Replace the o-ring if necessary.











2. Remove the oil pump (3)(Figure 6) from the rear output shaft (2).










3. Remove rear case (2)-to-front case (1) bolts (3)(Figure 7).










4. Remove the rear output shaft bearing inner snap-ring (3)(Figure 8) from the output shaft (1) using suitable snap-ring pliers.










5. Remove the rear output shaft bearing inner snap-ring (3)(Figure 9) from the output shaft (1).










6. Loosen rear case (2) with pry tool to break sealer bead. Insert tool at each end of case (Figure 10).










7. Unseat rear case from alignment dowels.
8. Remove the rear case (2) from the front case (1)(Figure 11).

FRONT OUTPUT SHAFT AND DRIVE CHAIN










1. Remove the oil pick-up tube (3)(Figure 12) and screen (2) from the front case half (1).










2. Remove the shift rail spring (2)(Figure 13) from the shift rail (1).










3. Remove the front output shaft (1) drive sprocket (2) retaining ring (3)(Figure 14).










4. Remove the rear output shaft (1) drive sprocket (2) retaining ring (3)(Figure 15).










5. Pull front sprocket (3)(Figure 16), rear sprocket, and chain (2) upward until clear of the front and rear output shaft sprocket splines.
6. Remove chain and sprockets as an assembly.