Disassembly

Special Tool(s)

Disassembly











Transfer Case Disassembled View

1. Remove the transfer case from the vehicle.





2. Attach the transfer case to the special tool.

3. CAUTION:
^ Index-mark the rear output shaft and the flange.
^ The nut has a self-locking feature. Discard the nut after removing it.





Use the special tool to prevent the flange from turning. Remove the nut and the washer. Discard the nut.





4. Using a suitable puller, remove the flange.





5. Remove the oil seal if it remains on the rear output shaft.





6. Using the special tool, remove the oil seal.





7. Remove the spacer.





8. Remove the two bolts retaining the harness to the motor assembly and connector.





9. Remove the rear bolt.





10. Remove the front bolt and the motor assembly and connector.





11. Remove the bolts that retain the transfer case cover to the transfer case.





12. Remove the bolts that retain the transfer case to the transfer case cover.

13. NOTE: Position the assembly so that the front of the transfer case is facing downward.





Insert a breaker bar between the pry bosses, and separate the transfer case cover from the transfer case.





14. Remove the snap ring that retains the bearing in the case.





15. Using the special tools, remove the bearing.





16. Using the special tools, remove the needle bearing.





17. Remove the following:
1. Remove the shift collar hub.
2. Remove the return spring.
3. Remove the lockup collar and the lockup fork as an assembly.
4. Remove the electric shift cam assembly.
5. Remove the shift rail.





18. Remove the snap ring.





19. Remove the lockup hub and the sleeve return spring from the lockup collar.





20. Remove the snap ring and the spacer.





21. Remove the drive chain, the driven sprocket, and the drive sprocket as an assembly.





22. Remove the magnet and the oil strainer from the slot in the transfer case.





23. Remove the rear output shaft and the pump assembly as an assembly.





24. Rotate the pump assembly to align the keyway in the cover and the spring pin in the rear output shaft, and separate the pump from the shaft.

25. CAUTION: Do not let the front output shaft assembly fall out of the case while removing the snap ring.





Remove the snap ring.





26. Remove the front output shaft assembly.





27. Remove the reduction fork assembly and the reduction hub as an assembly.





28. Remove the six bolts retaining the front adapter assembly to the case.





29. Remove the front adapter assembly, the input shaft assembly, and the complete carrier assembly as an assembly.





30. Using snap ring pliers, expand the tangs of the large snap ring and remove the complete carrier assembly and the input shaft assembly from the front adapter.





31. Remove the large snap ring from the front adapter.





32. Using a suitable tool, remove the oil seal from the front adapter.





33. Remove the snap ring.





34. Using the special tool and a suitable press, remove the bearing.





35. Remove the thrust washer and the input shaft assembly.





36. Remove the snap ring, the thrust plate, and the sun gear.

37. NOTE: Remove and discard both the sleeve bearing and the needle bearing if either one is worn/damaged.





Using the special tools and a suitable press, remove the needle bearing and the sleeve bearing from the input shaft.





38. Using a suitable tool, remove the oil seal.





39. Remove the snap ring retaining the bearing to the case.





40. Using the special tools, remove the bearing.





41. Using a suitable tool, remove the oil seal.





42. Remove the shift fork facings.





43. Remove the electric shift cam from the shift shaft.

44. WARNING: Keep fingers away from spring ends. Failure to follow these instructions may result in personal injury.





Remove the torsion spring and the spacer from the shift shaft.