Disassembly

Transfer Case

















Transfer Case Disassembled View

















Disassembly

1. Remove the transfer case from the vehicle. For additional information, refer to Transfer Case Removal Removal.

2. Attach the transfer case to the Transmission Holding Fixture.





3. NOTE: Index-mark the rear output shaft and the flange.

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

Use the Drive Pinion Flange Holding Fixture to prevent the flange from turning. Remove and discard the flange nut and the washer.





4. Using a suitable puller and the Drive Pinion Flange Holding Fixture, remove the flange.





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





6. Using the Oil Seal Remover, remove and discard the rear output shaft seal.





7. Remove the spacer.





8. Remove the shift motor bracket bolt and the 3 shift motor bolts.





9. Remove the coil wire from the shift motor electrical connector.

1. Remove the inner retainer from the electrical connector.

2. Lift up on the lock tab and remove the wire from the electrical connector.





10. Remove the 9 transfer case cover bolts.





11. NOTE: Position the assembly so that the front of the transfer case is facing downward.

Using the pry bosses, separate the transfer case cover from the transfer case.





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





13. Using the Stator Bearing Remover with the Slide Hammer, remove the bearing.





14. Using the Collet with the Slide Hammer, remove the needle bearing.





15. Remove the following:

1. Shift collar hub.

2. Return spring.

3. Lockup collar and the lockup fork as an assembly.

4. Electric shift cam assembly.

5. Shift rail.





16. Remove the lockup hub snap ring.





17. Remove the lockup hub and the sleeve return spring from the lockup collar.





18. Remove the snap ring and the spacer.





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





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





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





22. 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.





23. NOTE: The height of the oil pump spring pin must be measured before removal so that during assembly, it can be installed at the correct height so that the oil pump shaft rotates with the rear output shaft.

Using a micrometer, measure and record the pump drive pin height above the diameter of the rear output shaft. Remove the drive pin from the rear output shaft.





24. NOTICE: Do not let the front output shaft assembly fall out of the case while removing the snap ring or damage to the component may occur.

Remove the snap ring. Discard the snap ring if it was damaged during removal.





25. Remove the front output shaft.





26. Remove the reduction fork and the reduction hub as an assembly.





27. Remove the 6 bolts retaining the front adapter to the case.





28. Remove the front adapter, input shaft and the complete carrier as an assembly.





29. Using snap ring pliers, expand the tangs of the large snap ring and remove the complete carrier and the input shaft from the front adapter.





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





31. Using a suitable tool, remove and discard the oil seal from the front adapter.





32. Remove the snap ring retaining the input shaft to the planet carrier.





33. Using the Bearing Puller and a suitable press, remove the bearing.





34. Remove the thrust washer and the input shaft.





35. Remove the snap ring, the thrust plate and the sun gear.





36. NOTE: Remove and discard both the sleeve bearing and the needle bearing if either one is worn/damaged.

Using the Input Shaft Bearing Remover, Shaft Bearing Cone Installer, Bearing Oil Seal Plate and a suitable press, remove the needle bearing and the sleeve bearing from the input shaft.





37. Using a suitable tool, remove and discard the oil seal.





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





39. Using the Stator Bearing Remover with the Slide Hammer, remove the bearing.





40. Using a suitable tool, remove and discard the oil seal.





41. Remove the shift fork facings.





42. Remove the electric shift cam from the shift shaft.





43. WARNING: Keep fingers away from spring ends when releasing the spring. Spring ends are under tension and will unwind with force. Failure to follow this instruction may result in injured fingers.

Remove the torsion spring and the spacer from the shift shaft.