Disassembly and Assembly
Special Tools
Material
1. Remove the heat shield.
2. Remove the damper.
3. WARNING: Make sure the special tool lock pin is secure.
Using the special tool, secure the transfer case to the bench.
4. Index-mark the rear output flange and the rear output shaft.
5. Remove the components in the order indicated in the following illustration and table.
6. To assemble, reverse the disassembly procedure.
Item 1: Rear Output Shaft Flange Nut Disassembly Note
1. Using the special tool to hold the rear output shaft flange, remove the nut.
Item 5: Oil Seal Disassembly Note
1. Using the special tools, remove the oil seal.
Item 6: Connector Interlock Disassembly Note
1. Remove the coil wire pin from the electrical connector.
1. Remove the connector interlock.
2. Remove the coil wire pin.
- Use electrical connector pin extractor tool.
Item 11: Transfer Case Shift Motor Disassembly Note
1. Remove the transfer case shift motor, front output shaft speed sensor and rear output shaft speed sensor as an assembly.
Item 16: Transfer Case Cover Disassembly Note
1. Separate the transfer case halves at the transfer case pry bosses.
Item 17: Front Output Shaft Rear Bearing Disassembly Note
1. Using the special tools, remove the front output shaft rear bearing.
Item 18: Rear Output Shaft Support Bearing Disassembly Note
1. Using the special tools, remove the rear output shaft support bearing.
Item 22: Clutch Coil Assembly Disassembly Note
1. Remove the coil assembly and the cam and coil housing assembly as one assembly.
Item 28: Clutch Pack Assembly Disassembly Note
1. CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as it was located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it into place. If the thrust washer is not in place, a transfer case clearance problem can occur.
Remove the clutch pack assembly.
Item 29: Clutch Pack Assembly Armature Disassembly Note
1. Remove the clutch pack assembly armature.
Item 30: Drive Chain Disassembly Note
1. Remove the drive chain, driven sprocket and drive sprocket as an assembly.
Item 35: Rear Output Shaft and Oil Pump Assembly Disassembly Note
1. CAUTION: Do not disassemble the oil pump assembly.
Remove the oil pump assemby and the rear output shaft as an assembly.
Item 36: Electric Shift Cam, Torsion Spring and Shift Shaft Disassembly Note
1. CAUTION: Do not disassemble the electric shift cam assembly.
Remove the electric shift cam assembly, torsion spring and shift shaft as an assembly.
Item 37: High-Low Collar Disassembly Note
1. Remove the high-low collar and reduction fork as an assembly.
Item 40: Front Planetary Gear Set Assembly Disassembly Note
1. Remove the front planetary gear set assembly.
1. Expand the snap ring.
2. Remove the front planetary gear set assembly.
2. Remove the components in the order indicated in the following illustration and table.
3. To assemble the front planetary gear set assembly, reverse the disassembly procedure.
Item 43: Snap Ring Disassembly Note
1. Holding the front output shaft flange, remove the snap ring and the front output shaft.
Item 45: Oil Seal Disassembly Note
1. Using the special tools, remove the oil seal.
Item 46: Front Output Shaft Support Bearing Disassembly Note
1. Using the special tools, remove the front output shaft support bearing.
Item 48: Input Seal Disassembly Note
1. Using the special tool, remove the input seal.
Item 49: Output Shaft Bushing Disassembly Note
1. Using a drift and a hammer, remove the output shaft bushing, if necessary.
Item 50: Bearing Disassembly Note
1. Using a drift and a hammer, remove the output shaft bearing, if necessary.
Item 52: Planetary Gear Carrier Support Bearing Disassembly Note
1. Using a suitable press and the special tool, remove the planetary gear carrier support bearing.
Item 1: Rear Output Shaft Flange Nut Assembly Note
1. Using the special tool to hold the rear output shaft flange, tighten the nut.
Item 6: Connector Interlock Assembly Note
1. Install the coil wire pin in the electrical connector.
1. Install the coil wire pin.
2. Install the connector interlock.
Item 11: Transfer Case Shift Motor Assembly Note
1. NOTE: Make sure the motor mounting surfaces are clean.
Apply a 3-mm (1/8-inch) bead of silicone gasket and sealant to the motor mounting surfaces on the case.
Item 12: Front Output Shaft Speed Sensor Assembly Note
1. CAUTION: Make sure the sensor seats flat against the boss.
Install the front output shaft speed sensor.
Item 13: Rear Output Shaft Speed Sensor Assembly Note
1. CAUTION: Make sure the sensor seats flat against the boss.
Install the rear output shaft speed sensor.
Item 14: Bolt Assembly Note
1. Install the bolts, tighten them evenly in a star pattern.
Item 16: Cover Assembly Note
1. CAUTION: Applying too much silicone gasket and sealant can plug the fluid filter and cause transfer case failure.
NOTE: Make sure the transfer case mating surfaces are clean.
Apply a 3-mm (1/8-inch) bead of sealant to the transfer case mating surfaces.
2. Position the transfer case halves together.
Item 17: Front Output Shaft Rear Bearing Assembly Note
1. Using the special tools, press the front output shaft rear bearing into the case.
Item 18: Rear Output Shaft Support Bearing Assembly Note
1. Using the special tools, press the rear output shaft support bearing into the case.
Item 23: Cam and Coil Housing Assembly Assembly Note
1. Install the apply cam and the coil housing as an assembly.
Item 28: Clutch Pack Assembly Note
1. CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack on the bench in the same position as it was located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem can occur.
Install the clutch pack assembly.
Item 29: Clutch Pack Assembly Note
1. Install the clutch pack armature.
Item 32: Drive Sprocket Assembly Note
1. Install the drive chain, driven sprocket and drive sprocket as an assembly.
Item 38: Reduction Shift Fork Assembly Note
1. Install the reduction shift fork and high-low collar as an assembly.
Item 45: Oil Seal Assembly Note
1. Using the special tool, install the oil seal.
Item 46: Bearing Assembly Note
1. Using the special tools, press the front output shaft support bearing into the case.
Item 47: Shifter Shaft Seal Assembly Note
1. CAUTION: Do not crush the seal.
Using the special tools, install the shifter shaft seal.
Item 48: Input Seal Assembly Note
1. Using the special tool, install the input seal.
Item 49: Output Shaft Bushing Assembly Note
1. CAUTION: Do not crush the bearing cage.
If removed, using a suitable press and the special tool, install the output shaft bushing.
Item 50: Output Shaft Bearing Assembly Note
1. CAUTION: Do not crush the bearing cage.
If removed, using a suitable press and the special tool, install the output shaft bearing.
Item 52: Planetary Gear Carrier Support Bearing Assembly Note
1. If removed, using a suitable press, install the planetary gear carrier support bearing.