Disassembly

DISASSEMBLY
Position transfer case on shallow drain pan. Remove drain plug and drain lubricant remaining in case.


REAR RETAINER AND OIL PUMP





1. Remove rear retainer bolts (Fig. 5).





2. Remove rear bearing locating ring access plug (Fig. 6).





3. Loosen rear retainer with pry tool to break sealer bead. Pry only against retainer boss as shown (Fig. 7).
4. Remove rear retainer as follows:





a. Spread rear bearing locating ring with snap ring pliers (Fig. 8).





b. Then slide retainer off mainshaft and rear bearing (Fig. 9).
5. Remove rear bearing snap-ring.
6. Remove rear bearing. Note position of bearing locating ring groove for assembly reference.





7. Disengage oil pickup tube from oil pump and remove oil pump assembly (Fig. 10).





8. Remove pick-up tube O-ring from oil pump (Fig. 11), if necessary. Do not disassemble the oil pump, it is not serviceable.


COMPANION FLANGE
1. Remove front companion flange nut with socket and impact wrench.
2. Remove companion flange. If flange is difficult to remove by hand, remove it with bearing splitter, or with standard two jaw puller. Be sure puller tool is positioned on flange and not on slinger, as slinger will be damaged.
3. Remove seal washer from front output shaft. Discard washer as it should not be reused.


REAR CASE
1. Support transfer case so rear case is facing upward.





2. Remove bolts holding front case to rear case. The case alignment bolt require flat washers (Fig. 12).





3. Loosen rear case with flat blade screwdriver to break sealer bead. Insert screwdriver blade only into notches provided at each end of case (Fig. 13).





4. Remove rear case (Fig. 14).


PROGRESSIVE COUPLING





1. Remove oil pump locating snap-ring and progressive coupling thrust washer from the mainshaft (Fig. 15).
2. Remove progressive coupling from mainshaft (Fig. 15).


FRONT OUTPUT SHAFT AND DRIVE CHAIN





1. Remove oil pickup tube from rear case (Fig. 16).





2. Remove drive gear snap-ring (Fig. 17).
3. Disengage drive gear (Fig. 17). Pry gear upward and off mainshaft as shown.
4. Remove front output shaft, drive chain and drive gear as assembly (Fig. 17).
5. Remove output shaft drive gear snap ring.
6. Remove output shaft drive gear from output shaft.


MAINSHAFT
1. Remove mainshaft from the input gear pilot bearing.

NOTE: Loose needle bearings are used to support the drive sprocket hub on the mainshaft. Do not lift mainshaft by drive sprocket hub or needle bearings will become dislodged.

2. Wrap rag around mainshaft underneath drive sprocket hub and remove drive sprocket hub from mainshaft. Be sure to retrieve all the drive sprocket hub needle bearings.


INPUT GEAR
1. Turn front case on side so front bearing retainer is accessible.





2. Remove front bearing retainer bolts (Fig. 18).
3. Remove front bearing retainer as follows:





a. Loosen retainer with flat blade screwdriver to break sealer bead. To avoid damaging case and retainer, position screwdriver blade only in slots provided in retainer (Fig. 19).
b. Then remove retainer from case and gear.





4. Remove snap-ring that retains input gear shaft in front bearing (Fig. 20).
5. Remove oil seals from following components:
- front bearing retainer.
- rear retainer.
- case halves.