Disassembly

Transfer Case

Part 2 Of 4:

Part 3 Of 4:

Special Tool(s)

Disassembly
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.

CAUTION: The nut has a self-locking feature. Discard the nut and the washer after removing them.

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





4. Using a suitable puller, remove the flange.





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





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





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








8. 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.
^ Remove the old sealant. Do not damage the mating surfaces of the aluminum case.





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





10. Remove the bearing, spacer and seal.
1 From outside of the case, remove the bearing with a suitable drift.
2 Remove the spacer.
3 From inside the case,, remove the seal using a suitable drift.





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





12. 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 shift rail.








13. Remove the snap ring, then remove the lockup hub and the sleeve return spring from the lockup collar.





14. Remove the snap ring and the spacer.





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





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





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





18. 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.
^ If it is necessary to install a new spring pin:
^ Measure and record the spring pin height above the output shaft diameter.
^ Remove the spring pin.








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

Holding the bottom of the front output shaft, remove the snap ring. Discard the snap ring if deformed during removal. Remove the front output shaft assembly.





20. Remove the reduction fork assembly and the reduction hub as an assembly.
21. Remove the case from the holding fixture and place it on the bench.





22. NOTE: Rotate the front case until the front adapter is pointing upward.

Remove the front adapter assembly to case bolts.





23. Remove the front adapter, the input shaft, and the complete carrier as an assembly.
^ Lightly tap around the front adapter to break the seal.
^ Remove the old sealant. Clean the mating surface of the carrier.





24. 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.
^ Expand the tangs of the large snap ring in the main drive gear bearing retainer. With the input shaft against the bench, push the main drive gear bearing retainer down and slide it off the bearing. Lift the input shaft and front planet from the main drive gear bearing retainer.





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





26. Using a suitable tool, remove the oil seal from the front adapter.
^ Using a suitable drift, remove from inside the front adapter.





27. Remove the snap ring.





28. Using the special tool, press the bearing from the input shaft.





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





30. Disassemble the planetary gear.
1 Remove the snap ring.
2 Remove the thrust plate.
3 Remove the sun gear.





31. NOTE: Inspect the bushing and bearing. If either one is worn or damaged, remove and discard both the bushing and the needle bearing. Install new ones as a set.

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





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





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





34. Using the special tools, remove the bearing.





35. Remove the shift fork facings.





36. Remove the set screws.





37. NOTE: The shift lever and shift cam do not have to be disassembled unless new components are being installed. Turn the front case over.

Remove the clip, then pry the shift shaft out of the front case and the shift cam.
^ Remove and discard the O-ring from the shift shaft.





38. Remove the four-wheel drive switch.