Part 1
Transfer Case - Electronic ShiftSpecial Tool(s) (Part 1):
Special Tool(s) (Part 2):
Special Tool(s) (Part 3):
Special Tool(s) (Part 4):
Material:
Electric Shift Transfer Case (Part 1):
Electric Shift Transfer Case (Part 2):
Disassembly (Steps 1-29)
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.
2. Remove the gearmotor encoder assembly.
3. CAUTION: Do not use air tools to remove the plugs.
Remove the drain and fill plugs.
4. Remove and discard the front output nut.
^ Use the special tool to prevent the flange from turning.
5. Using a suitable 2- or 3-jaw puller, remove the flange.
6. Remove and discard the rear output nut.
^ Use the special tool to prevent the flange from turning.
7. Using a suitable 2- or 3-jaw puller, remove the flange.
8. Remove the slinger from the front flange and the rear flange, if necessary.
9. Using the special tools, remove the rear output seal.
10. Remove and discard the 8 rear retainer bolts.
11. Using the special tool, separate the rear retainer from the rear case and remove the rear retainer.
12. Using the special tools and a suitable press, remove the needle bearing.
13. Disconnect the oil tube and remove the oil pump assembly.
14. 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.
15. Remove and discard the 25 case bolts.
16. Using the special tool, separate the case halves and remove the rear case.
17. Remove the oil tube.
18. Remove the ball bearing retaining ring.
19. Using the special tools and a suitable press, remove the ball bearing.
20. Using the special tool, remove the needle bearing.
21. Remove the chip collector magnet.
22. Remove the driven sprocket retaining ring.
23. Remove the drive sprocket retaining ring.
24. Remove the mode spring.
25. Remove the drive sprocket, driven sprocket and the drive chain as an assembly.
26. Remove the mainshaft and the mode fork as an assembly.
27. Slide the mode fork and synchronizer sleeve off the mainshaft, and separate the components.
28. Place the mainshaft in a soft-jawed vise with the threaded end upward.
29. Remove the clutch gear.
