Disassembly

Transfer Case

Part 1 Of 4:

Part 2 Of 4:

Part 3 Of 4:

Part 4 Of 4:

Special Tool(s)

Disassembly
All transfer cases

CAUTION: Discard all nuts, bolts, and retaining rings after removing them from the transfer case. Install all new fasteners during transfer case assembly.





1. Attach the transfer case to the special tool.





Electric shift transfer case
2. Remove the gearmotor encoder assembly.





Manual shift transfer case
3. Remove the 3 position switch.





All transfer cases
4. CAUTION: Do not use air tools to remove the plugs.

Remove the drain and fill plugs.





5. Remove and discard the nut.
^ Use the special tool to prevent the flange from turning.





6. Using a suitable 2- or 3jaw puller, remove the flange.





7. Remove and discard the nut.
^ Use the special tool to prevent the flange from turning.





8. Using a suitable 2- or 3jaw puller, remove the flange.





9. Remove the slinger from the front flange and the rear flange, if necessary.





10. Using the special tools, remove the rear output seal.





11. Remove and discard the eight bolts retaining the rear retainer to the rear case.





12. Remove the rear retainer.
^ Use the special tool to separate the rear retainer from the rear case.





13. Using the special tools and a suitable press, remove the needle bearing.





14. Disconnect the oil tube and remove the oil pump assembly.





15. Remove and discard the retaining ring.
1 Install the special tool.
2 Lift up on the shaft, and remove and discard the retaining ring.
^ Remove the special tool.





16. Remove and discard the 25 bolts retaining the rear case to the front case.





17. Remove the rear case.
^ Use the special tool to separate the case halves.





18. Remove the oil tube.





19. Remove the ball bearing retaping ring.





20. Using the special tools and a suitable press, remove the ball bearing.





21. Using the special tool, remove the needle bearing.





22. Remove the chip collector magnet.





23. Remove the driven sprocket retaining ring.





24. Remove the drive sprocket retaining ring.





25. Remove the mode spring.





26. Remove the sprockets and chain as an assembly.





27. Remove the mainshaft and the mode fork assembly as an assembly.





28. Slide the mode fork and synchronizer sleeve off the mainshaft, and separate the components.
^ Mode sleeve for mechanical shift or synchronizer sleeve for electric shift.

29. Place the mainshaft in a soft jawed vise with the threaded end upward.





30. Remove the clutch gear.





31. Remove the retaining ring and the synchronizer hub.





Electric shift transfer case
32. Remove the outer ring.





33. Remove the middle ring.





34. Remove the inner ring.





All transfer cases
35. Remove the drive sprocket hub.
36. Inspect all of the components for wear and damage.





37. Inspect the mode fork pads for wear.





38. NOTE: Rotate the sector assembly to the 4-wheel high position for easy removal.

Remove the range fork assembly and the range shift sleeve.





39. NOTE: Manual shift range fork shown, electric shift range fork similar.

Inspect the range fork pads for wear. If the pads are worn, discard the range fork, the pads, the mainshaft, and the sleeve.





40. Using the special tools, remove the input seal.





41. Remove and discard the retaining ring.
1 Install the special tool.
2 Remove and discard the retaining ring.
^ Remove the special tool.





42. Remove the planetary assembly.





43. Remove the input bearing retaining ring.





44. Using the special tool and a suitable press, remove the front input bearing.





45. Using the special tools, remove the front output seal.





46. Remove and discard the retaining ring.
1 Install the special tool.
2 Remove and discard the retaining ring.





47. Remove the special tool and the front output shaft.





48. Remove the front output ball bearing retaining ring.





49. Using the special tools and a suitable press, remove the front output ball bearing.





50. Remove the lock plate retaining ring.





51. Lift out the input gear.





52. Remove the lock plate.





53. Remove the front input gear thrust washer.





54. Remove the rear input gear thrust washer.





55. Inspect the gear teeth and thrust washers for wear and damage. Discard the planetary gear assembly, if necessary.





56. Remove the poppet assembly.





57. NOTE: If installing a new poppet spring, it must be like in color to the original poppet spring.

Disassemble the poppet screw, the spring, and the popper.





Manual shift transfer case
58. Remove the locknut, the washer, the lever, the spacer, and the sector assembly.





Electric shift transfer case
59. Remove the plastic retainer and the O-ring, and remove the sector assembly.





All transfer cases
60. Using the special tool, remove the sector shaft support (motor adapter for electric shift transfer case).





61. Remove and discard the support O-ring seal.