Part 1
Transfer Case - Electronic Shift
Electric Shift Transfer Case
Disassembly
All vehicles
NOTE: 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 Transmission Holding Fixture.
2. Remove the gearmotor encoder assembly.
3. Remove the drain and fill plugs.
4. Using the Drive Pinion Flange Holding Fixture to prevent the flange from turning, remove and discard the front output nut.
5. Using the 2 or 3 Jaw Puller, remove the flange.
Vehicles equipped with a flange
6. Using the Drive Pinion Flange Holding Fixture to prevent the flange from turning, remove and discard the rear output nut.
7. Using the 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 Slide Hammer with the Torque Converter Oil Seal Remover, remove the rear output seal.
Vehicles equipped with a slip yoke
10. Using a suitable tool, remove the rear output seal.
All vehicles
11. Remove and discard the 8 rear retainer bolts.
12. Using the Transfer Case Housing Spreader, separate the rear retainer from the rear case and remove the rear retainer.
13. Using the Front Pump Bushing Remover with the Handle 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 Output Shaft Rear Snap Ring Sleeve.
2. Lift up on the shaft and remove and discard the retaining ring.
- Remove the Output Shaft Rear Snap Ring Sleeve.
16. Remove and discard the 25 case bolts.
17. Using the Transfer Case Housing Spreader separate the case halves and remove the rear case.
18. Remove the oil tube.
19. Remove the ball bearing retaining ring.
20. Using the Drive Pinion Bearing Cup Installer with the Handle and a suitable press, remove the ball bearing.
21. Using the Universal Puller Set, 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 drive sprocket, driven sprocket and the drive chain as an assembly.
27. Remove the mainshaft and the mode fork as an assembly.
28. Slide the mode fork and synchronizer sleeve off the mainshaft, and separate the components.
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.
32. Remove the outer ring.
33. Remove the middle ring.
34. Remove the inner ring.
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: Manual shift range fork shown, electric shift range fork similar.
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 Torque Converter Oil Seal Remover with the Slide Hammer, remove the input seal.
41. Remove and discard the retaining ring.
1. Install the Input Shaft Snap Ring Sleeve.
2. Remove and discard the retaining ring.
- Remove the Input Shaft Snap Ring Sleeve.
42. Remove the planetary assembly.
43. Remove the input bearing retaining ring.
44. Using the Drive Pinion Bearing Cup Installer and a suitable press, remove the front input bearing.
45. Using the Torque Converter Oil Seal Remover with the Slide Hammer, remove the front output seal.
46. Remove and discard the retaining ring.
1. Install the Output Shaft Front Snap Ring Sleeve.
2. Remove and discard the retaining ring.
47. Remove the Output Shaft Front Snap Ring Sleeve and the front output shaft.
48. Remove the front output ball bearing retaining ring.
49. Using the Rear Axle Oil Seal Installer with the Handle and a suitable press, remove the front output ball bearing.
50. Remove the lock plate retaining ring.
51. Lift out the input gear.
- Inspect the input gear for wear or damage. Install a new gear if necessary.
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. Install a new planetary gear assembly, if necessary.
56. Remove the poppet assembly.
57. NOTE: If installing a new poppet spring, it must be similar in color to the original poppet spring.
Disassemble the poppet screw, the spring and the poppet.
58. Remove the plastic retainer and the O-ring, and remove the sector assembly.
59. Using the Sector Shaft Nut Socket, remove the motor adapter.
60. Remove and discard the support O-ring seal.
