Disassembly
Transfer Case - All Wheel Drive (AWD)
Transfer Case Exploded View - Torque On Demand (TOD) (Part 1):
Transfer Case Exploded View - Torque On Demand (TOD) (Part 2):
Disassembly
1. Clean the transfer case with solvent and dry with compressed air.
2. Using the special tool, secure the transfer case to the bench.
3. If not done previously, remove the drain plug and drain the fluid.
^ Drain the fluid and inspect for contamination. If heavy metallic or plastic contamination is noted, remove the transfer case and inspect for the source of contamination. Install new components as necessary.
4. Remove the wire connector spacer. Using an electrical connector pin extractor tool, remove the coil wire and pin.
5. Install a 102 mm (4.0 in) piece of 31.75 mm (1.25 in) I.D. conduit on the output shaft into the extension housing to protect it from damage and keep the bushing from separating from the housing. Remove the 6 extension housing bolts.
6. Using a soft-faced hammer, tap the extension housing to break the gasket seal and remove the extension housing.
^ If the extension housing bushing is dislodged during removal, a new extension housing bushing must be installed.
7. Remove the 3 coil-to-cover nuts and the coil.
8. Remove the rear output shaft snap ring.
9. NOTE: The bolts are self-tapping, and it is normal to find metal shavings while removing the cover.
Remove the 20 transfer case bolts.
10. Use the pry bosses to separate the cover from the case.
11. Remove the bearing.
12. Remove the inboard bearing snap ring.
13. Remove the coil housing and thrust washer assembly.
14. Remove the 3 ball bearings and the apply cam.
15. Remove the wave spring.
16. Remove the snap ring.
17. Remove the clutch pack assembly.
18. Remove the spacer.
19. Remove the drive chain and sprockets as an assembly.
20. Remove the magnet from its slot in the case.
21. Remove the thrust bearing race.
22. Remove the thrust bearing.
23. Remove the thrust bearing race.
24. Remove the output shaft hub.
25. Remove the oil pump and inlet tube.
26. Remove the output shaft.
27. Remove the input gear.
28. Remove the snap ring.
29. Remove the input shaft support bearing.
30. Remove the input seal.
31. Remove the snap ring and the front output shaft.
32. Using 2 crow's foot prybars, remove the front output shaft bearing.
33. Remove the front output shaft seal.
34. Remove the dust shield, if necessary.
