Clutch Pack and Clutch Cam (Transfer Case Assembly)

Clutch Pack and Clutch Cam (Transfer Case Assembly)






Disassembly
1. Remove the lockup fork spring.





2. Remove the thrust bearing and cam and coil housing assembly from the output shaft.

Note: When the cam and coil housing assembly is removed, the cam balls may be detached together with the housing. Pay affection not to lose the ball.

3. Remove the cam ball (3 pieces).





4. Remove the cam pulley.





5. Remove the wave spring.





6. Using snap ring pliers, remove the snap ring.

Note: Use care to prevent damage to snap ring.





7. Remove the armature plate, insulator washer and clutch pack assembly as a package.

Reassembly





1. Install the clutch pack assembly which the multi clutch plate is orderly installed to the output shaft.

Note:
- Install the clutch pack assembly while adjusting the phase of both the clutch housing and drive sprocket
- During installation, the plate of the clutch pack assembly may slide out of this fixed position (the correct position is shown in the illustration). If this occurs, remove all of the clutch plates of the clutch pack assembly and reinstall them to their correct position.





2. Install the insulator washer and armature plate to the clutch pack assembly.





3. Using snap ring pliers, install the snap ring to the output shaft.





4. Install the wave spring to the output shaft.
5. Install the cam pulley.





6. Place a ball on each groove of the cam pulley.
7. Install the cam and coil housing to the output shaft.
8. Install the thrust bearing.





9. Install the lockup fork spring.