Transfer Case - Electronic Shift
Transfer Case - Electronic Shift
Transfer Case Exploded View - Electronic Shift
Disassembly
NOTE: Discard all seals after removing them.
1. Clean the transfer case with solvent and dry with compressed air.
2. Using the Transmission Holding Fixture, secure the transfer case to the bench.
3. If not done previously, remove the drain plug and drain the fluid.
4. Using a suitable seal puller, remove the rear output shaft seal.
5. Remove the inner connector retainer. Press the release tab and remove the coil wire from the electric shift motor electrical connector.
6. Remove the 3 transfer case shift motor bolts, bracket bolt and loosen the 2 bracket nuts.
7. NOTE: The transfer case bolts are self tapping, and it is normal to find metal shavings while removing the cover.
Remove the 20 transfer case bolts.
8. Using the pry bosses, separate the transfer case covers.
9. Remove the 3 transfer case field coil nuts, washers and transfer case field coil.
10. Using the Bearing Cup Remover with the Slide Hammer, remove the rear output shaft bearing.
11. Using the Bearing Cup Remover with the Slide Hammer, remove the front output shaft bearing.
12. Remove the shift collar hub snap ring.
13. Remove the coil housing.
14. Remove the shift fork.
1. Remove the lockup hub.
2. Remove the shift fork and spring.
15. 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.
16. NOTE: Remove the drive chain and sprockets as an assembly.
Remove the drive chain, sprockets and the thrust washer.
17. Remove the magnet from its slot in the case.
18. 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.
19. Remove the shift rail.
20. Remove the shift fork and the reduction hub.
1. Remove the shift fork.
2. Remove the reduction hub.
21. NOTE: The electric shift cam is serviced as an assembly. Do not disassemble the shift cam assembly.
Remove the electric shift cam assembly.
22. Remove the front planet carrier.
23. Using the Oil Seal Remover, remove the input seal.
24. Remove the thrust bearing. Using a drift and a hammer, remove the needle bearing, if necessary.
25. Remove the ring gear.
1. Remove the ring gear snap ring.
2. Remove the ring gear.
26. Using the Stator Bearing Remover with the Slide Hammer, remove the front planet carrier bearing.
27. NOTICE: Do not let the front output shaft fall while removing the snap ring or damage to the component may occur.
Remove the front output shaft.
1. Remove the front output shaft snap ring.
2. Remove the front output shaft.
28. Using the Stator Bearing Remover with the Slide Hammer, remove the front output shaft bearing.
29. Using the Bearing Cup Remover with the Slide Hammer, remove the front output shaft seal.
Assembly
1. Using a suitable press and the Bearing Cup Installer with the Handle, install the front output shaft bearing.
2. Using the Input Shaft Oil Seal Installer, install the front output shaft seal.
3. Install the front output shaft.
1. Position the front output shaft.
2. Install the front output shaft snap ring.
4. Using a press and a suitable bearing installer, install the front planet carrier bearing.
5. Position the ring gear in the case. Install the ring gear snap ring.
6. If removed, using a suitable press and the Input Shaft Bearing Installer, install the needle bearing into the front planet carrier.
7. Install the front planet carrier and the thrust bearing.
8. Using the Shaft Oil Seal Protector and the Input Shaft Oil Seal Installer, install the input seal.
9. Install the electric shift cam assembly.
10. Install the shift fork and the reduction hub.
11. Install the shift rail.
12. Install the oil pump, output shaft and the thrust washer.
13. Install the magnet into its slot in the case.
14. Install the drive chain and the sprockets as an assembly.
15. Install the lockup hub assembly. If the lockup hub assembly was disassembled, carry out the following steps.
1. Position the lockup collar.
2. Install the lockup collar springs.
3. Install the lockup hub.
4. Install the armature.
5. Install the lockup hub snap ring.
16. Install the lockup hub and the shift fork and spring.
17. Install the coil housing.
18. Install the snap ring.
19. Using the Mainshaft Bearing Installer, install the rear output shaft bearing.
20. Using the Mainshaft Bearing Installer, install the front output shaft bearing.
21. Install the transfer case field coil, washers and the 3 nuts.
- Tighten to 10 Nm (89 lb-in).
22. NOTICE: If too much silicone sealant is used when sealing the cover to the case, the excess sealant can plug the fluid filter and cause transfer case failure.
Apply a small bead of silicone sealant to the mating surface of the case and cover.
23. Position the 2 transfer case halves and tighten the 20 bolts in the sequence shown.
- Tighten to 24 Nm (18 lb-ft).
24. Using the Input Shaft Oil Seal Installer, install the oil seal, if removed.
25. Apply a small bead of silicone sealant to the transfer case shift motor mating surface.
NOTICE: The following steps need to be performed in the correct order when installing the transfer case shift motor. Failure to follow the steps in the correct order may result in damage to the component.
26. Install the transfer case shift motor and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).
27. Install the transfer case shift motor bracket bolt.
- Tighten to 10 Nm (89 lb-in).
28. Secure the 2 transfer case shift motor bracket nuts.
- Tighten to 3 Nm (27 lb-in).
29. NOTE: After the coil wire is inserted into the connector, gently pull the wire back to verify the pin is locked inside the connector.
Insert the coil wire pin in the electrical connector and install the inner connector retainer.
30. Remove the transfer case from the Transmission Holding Fixture.