MP3023 Transfer Case - Disassembly

DISASSEMBLY

Special Tools:

NOTE: If the transfer case assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the Scan Tool.

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

2. Using Holder (1), remove the rear flange (2) nut.

3. Remove the rear output flange from the main shaft. If necessary, use a suitable 2 or 3 jaw puller to remove the output flange.

4. Remove encoder screws and the encoder from the transfer case.

5. Remove the shift shaft snap ring from the transfer case.

6. Remove shift motor bolts and the shift motor from the transfer case.

7. Remove the o-ring from the shift motor.

8. Using a suitable pry tool, remove shift motor seal from the transfer case.

9. Remove the worm shaft snap ring from the transfer case.

CAUTION: Carefully unthread (rotate clockwise) the worm shaft to remove it from the transfer case. Failure to follow this caution may result in parts damage.

10. Remove the worm shaft from the transfer case

NOTE: Some prying may be necessary to break the seal between the front and rear case. Use care to not damage the sealing surfaces.

11. Remove the bolts retaining the rear housing to the front housing and separate the housings.

12. Remove the output shaft thrust washer.

13. Remove the oil pump assembly.

14. Remove oil tube (1) from the oil pump and remove the o-ring (2).

15. Remove the pick-up magnet from the magnet pocket.

NOTE: For ease of installation note the orientation of the worm shaft drive gear inner splines to the shift shaft outer splines.

16. Remove the worm drive gear.

NOTE: For ease of installation note the orientation of the clutch cam inner splines to the shift shaft outer splines.

17. Remove the clutch cam.

18. Remove the clutch upper snap ring.

19. Remove the clutch shim.

20. Remove the thrust collar.

21. Remove the upper thrust bearing race.

22. Remove the upper thrust bearing.

23. Remove the upper shift lever.

24. Remove the shift lever balls.

25. Remove the lower shift lever.

26. Remove the lower thrust bearing.

27. Remove the lower thrust bearing race.

28. Remove the clutch apply piston.

NOTE: For ease of installation note the assembly orientation of the 4 identical springs.

29. Remove the clutch return springs.

30. Remove the clutch pack.

31. Remove the inner clutch hub.

32. Remove the clutch drum thrust washer (1) and snap ring (2).

33. Remove the outer clutch drum from the mainshaft drive sprocket.

34. Remove the front drive sprocket, mainshaft drive sprocket and drive chain as one.

35. Remove the shift shaft spacer.

NOTE: For ease of installation note the orientation of the barrel cam inner splines to the shift shaft outer splines.

36. Remove the barrel cam.

37. Remove the shift shaft.

38. Remove the main shaft from the transfer case.

39. Remove the detent assembly.

NOTE: For ease of assembly note the orientation of the shift fork to the shift rail.

40. Remove the range shift rail assembly and range sleeve. Remove the rail, bracket, spring and washers from the shift fork.