Disassembly

Transfer Case - Electronic Shift

Transfer Case Exploded View - Electronic Shift (Part 1):

Transfer Case Exploded View - Electronic Shift (Part 2):

Transfer Case Exploded View - Electronic Shift (Part 3):

Disassembly

NOTE: Discard all seals after removing them.

1. Remove the transfer case.
2. Clean the transfer case with solvent and dry with compressed air.
3. Using the special tool, secure the transfer case to the bench.





4. If not done previously, remove the drain plug and drain the fluid.





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





6. Remove the wire connector spacer. Using an electrical connector pin extractor tool, remove the coil wire and the ground wire from the electric shift motor electrical connector.





7. Remove the transfer case shift motor.
1 Remove the 4 transfer case shift motor bolts.
2 Remove the transfer case shift motor.





8. Remove the extension housing.
1 Remove the 6 extension housing bolts.
2 Remove the extension housing.





9. Lift up on the output shaft, then remove the rear output shaft snap ring.





10. NOTE: The bolts are self-tapping, and it is normal to find metal shavings while removing the cover.

Remove the 20 transfer case bolts.





11. Using the pry bosses, separate the transfer case covers.





12. Remove the coil.
1 Remove the 3 coil-to-cover nuts.
2 Remove the coil.





13. Using the special tools, remove the rear output shaft bearing.





14. Using the special tools, remove the front output shaft bearing.





15. Remove the shift collar hub snap ring.





16. Remove the coil housing.





17. Remove the shift fork.
1 Remove the lockup hub.
2 Remove the shift fork and spring.





18. NOTE: Remove the lockup hub assembly as a single unit. If disassembly is required, proceed with the following.

Disassemble the lockup hub assembly.
1 Remove the lockup hub snap ring.
2 Separate the lockup collar.
3 Separate the 2 lockup springs.
4 Separate the lockup hub.
5 Remove the armature.





19. Remove the spacer.





20. Remove the drive chain and sprockets as an assembly.





21. Remove the magnet from its slot in the case.





22. NOTE: The pump assembly is not repairable.

Remove the oil pump and the output shaft as an assembly. Remove the oil pump from the output shaft.





23. Remove the shift rail.





24. Remove the shift fork and the reduction hub.
1 Remove the shift fork.
2 Remove the reduction hub.





25. NOTE: The electric shift cam is serviced as an assembly. Do not disassemble shift cam assembly.

Remove the electric shift cam assembly.





26. Using the special tool, remove the input seal.





27. CAUTION: Do not let the front planet carrier fall while removing the snap ring. Damage to the carrier could occur.

Remove the front planet carrier.
1 Remove the front planet carrier snap ring.
2 Remove the front planet carrier.





28. If necessary, using the special tools, remove the bushing from the front planet.





29. Using a drift and a hammer, remove the needle bearing, if necessary.





30. Remove the ring gear.
1 Remove the ring gear snap ring.
2 Remove the ring gear.





31. Remove the front planet carrier bearing snap ring. Then, using the special tools, remove the front planet carrier bearing.





32. Remove the front output shaft.
1 Remove the front output shaft snap ring. Do not let the front output shaft fall while removing the snap ring.
2 Remove the front output shaft.





33. Using the special tools, remove the front output shaft bearing.





34. Using the special tools, remove the front yoke-to-flange seal.





35. Using a suitable pry tool, remove the electric shift motor seal.





36. Remove the dust shield, if necessary.