Part 1

DISASSEMBLY
REAR RETAINER REMOVAL

Output Boot-Typical:

1. Remove output shaft boot. Spread band clamp that secures boot on slinger with a suitable awl. Then slide boot off shaft.

Rear Slinger Removal:

2. Using puller MD-998056-A, remove rear slinger.

Slinger Stop Spacer And Snap-Ring:

3. Remove slinger stop spacer and snap-ring from output shaft.

Rear Seal Removal:

4. Remove rear seal from retainer. Use pry tool, or collapse seal with punch to remove it.

Rear Bearing I.D. Retaining Ring Removal:

5. Remove rear output bearing I.D. retaining ring.
6. Remove speedometer adapter.
7. Remove rear retainer bolts.

Rear Retainer Removal:

8. Remove rear retainer. Tap retainer with mallet and pry upward to break sealer bead. Then slide retainer off case and output shaft.

Oil Pump Removal:

9. Remove rear bearing O.D. retaining ring with snap ring pliers. Then tilt pump and slide it off output shaft

Pickup Tube O-Ring Location:

10. Remove pickup tube O-ring from pump but do not disassemble pump; it is not a repairable part.
11. Remove seal from oil pump with pry tool.

Spline And Dowel Bolt Locations:

12. Remove bolts attaching rear case to front case. Note position of the two black finish bolts at each end of the case. These bolts go through the case dowels and require a washer under the bolt head.

Loosening/Removing Rear Case:

13. Remove rear case from front case. Insert screwdrivers into slots cast into each end of case. Then pry upward to break sealer bead and remove rear case.

CAUTION: Do not pry on the sealing Surface of either case half as the surfaces will become damaged.

Oil Pickup Screen, Hose And Tube Removal:

14. Remove oil pickup tube and screen from rear case.

YOKE AND RANGE LEVER REMOVAL
1. Remove front yoke nut:
a. Move range lever to 4L, position.

Yoke Nut Removal:

b. Remove nut with socket and impact wrench.

Yoke Removal:

2. Remove yoke. If yoke is difficult to remove by hand, remove it with bearing splitter, or with standard two jaw puller. Be sure puller tool is positioned on yoke 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.

Range Lever Removal:

4. Remove nut and washer that attach range lever to sector shaft. Then move sector to neutral position and remove range lever from shaft.

FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL

Drive Sprocket Snap-Ring Removal:

1. Remove drive sprocket snap-ring.

Drive Sprocket And Chain Removal:

2. Remove drive sprocket and chain.

Removing Front Output Shaft:

3. Remove front output shaft.

SHIFT FORKS AND MAINSHAFT REMOVAL AND DISASSEMBLY

Detent Component Removal:

1. Remove shift detent plug, spring and pin.
2. Remove seal plug from low range fork lockpin access hole. Then move shift sector to align low range fork lockpin with access hole.
3. Remove range fork lockpin with size number one easy-out tool as follows:
a. Insert easy-out tool through access hole in side of transfer case and into lock-pin.
b. Tap easy-out tool into lock-pin with hammer until tool is securely engaged into the lock-pin.
c. Install a t-handle, such as from a tap and die set, onto the easy-out tool.
d. Securely tighten the t-handle onto the tool.
e. In one motion, pull upward and turn the t-handle counter-clockwise to remove the lock-pin.

Shift Rail Removal:

4. Remove shift rail by pulling it straight up and out of fork.

Mode Fork And Mainshaft Removal:

5. Remove mode fork and mainshaft as assembly.

Mode Fork And Sleeve Removal:

6. Remove mode shift sleeve and mode fork assembly from mainshaft. Note position of mode sleeve in fork and remove sleeve.

Intermediate Clutch Shaft Snap-Ring Removal:

7. Remove intermediate clutch shaft snap-ring.

Clutch Shaft Thrust Ring Removal:

8. Remove clutch shaft thrust ring.

Intermediate Clutch Shaft Removal:

9. Remove intermediate clutch shaft.

Differential Snap-Ring Removal:

10. Remove differential snap-ring.

Differential Removal:

11. Remove differential.
12. Remove differential needle bearings and both needle bearing thrust washers from mainshaft.

Disengaging Low Range Fork:

13. Slide low range fork pin out of shift sector slot.

Low Range Fork And Hub Removal:

14. Remove low range fork and hub.

Shift Sector Position:

15. Remove shift sector.

Sector Bushing And O-Ring Removal:

16. Remove shift sector bushing and O-ring.

INPUT GEAR/LOW RANGE ASSEMBLY REMOVAL AND DISASSEMBLY
1. Remove front bearing retainer bolts.

Front Bearing Retainer Removal:

2. Remove front bearing retainer. Carefully pry retainer loose with screwdriver. Position screwdriver in slots cast into retainer.

Input Gear Snap-Ring Removal:

3. Remove input gear snap-ring.

Input And Low Range Gear Assembly Removal:

4. Remove input/low range gear assembly from bearing with Tool Handle C-4171 and Tool 7829A.

Low Range Gear Snap-Ring Removal/Installation:

5. Remove low range gear snap-ring.

Low Range Gear Disassembly:

6. Remove input gear retainer, thrust washers and input gear from low range gear.

Inspecting Low Range Annulus Gear:

7. Inspect low range annulus gear. Gear is not a serviceable component. If damaged, replace gear and front case as assembly.
8. Remove oil seals from following components:
- front bearing retainer.
- rear retainer.
- oil pump.
- case halves.

DIFFERENTIAL DISASSEMBLY
1. Mark differential case halves for reference.
2. Remove differential case bolts.
3. Invert differential on workbench.

Separating Differential Case Halves:

4. Separate top case from bottom case. Use slots in case halves to pry them apart.

Planet Gears And Thrust Washer Removal:

5. Remove thrust washers and planet gears from case pins.

Mainshaft And Sprocket Gear Removal:

6. Remove mainshaft and sprocket gears from bottom case. Note gear position for reference before separating them.

ASSEMBLY
Lubricate transfer case components with automatic transmission fluid or petroleum jelly (where indicated) during assembly.

CAUTION: The bearing bores in various transfer case components contain oil feed holes. Make sure replacement bearings do not block the holes.

BEARING AND SEAL INSTALLATION

Front Output Shaft Front Bearing Snap-Ring Removal:

1. Remove snap-ring that retains front output shaft front bearing in case. Then remove bearing. Use hammer handle, or hammer and brass punch to tap bearing out of case.

Front Output Shaft Front Bearing Installation:

2. Install new front output shaft front bearing with Tool. Handle C-4171 and Installer 8033A with the tapered cone upward.
3. Install front bearing snap-ring.

Remove Front Output Shaft Seal:

4. Remove front output shaft seal using an appropriate pry tool or slide-hammer mounted screw.

Install Front Output Shaft Seal:

5. Install new front output shaft oil seal with Installer 6952-A.

Input Gear Bearing Removal:

6. Remove input gear bearing with Tool Handle C-4171 and Remover C-4210.
7. Install snap-ring on new input gear bearing.

Seating Input Gear Bearing:

8. Install new input gear bearing with 'pool Handle C-4171 and Remover C-4210. Install bearing far enough to seat snap-ring against case.

Remove Input Gear Pilot Bearing:

9. Remove the input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer.

Install Input Gear Pilot Bearing:

10. Install new pilot bearing with Installer 8128 and Handle C-4171.

Front Bearing Retainer Seal Installation:

11. Install new seal in front bearing retainer with Installer 7884.

Remove Front Output Shaft Rear Bearing:

12. Remove output shaft rear bearing with the screw and jaws from Remover L-4454 and Cup 8148.

Install Front Output Shaft Rear Bearing:

13. Install new bearing with Tool Handle C-4171 and Installer 5066. Lubricate bearing after installation.

Oil Pump Seal Installation:

14. Install new seal in oil pump feed housing with Special Tool 7888.

Pickup Tube O-Ring Installation:

15. Install new pickup tube O-ring in oil pump.

DIFFERENTIAL ASSEMBLY
1. Lubricate differential components with automatic transmission fluid.

Installing Differential Sprocket Gear:

2. Install sprocket gear in differential bottom case.

Installing Mainshaft And Planet Gears:

3. Install differential planet gears and new thrust washers. Be sure thrust washers are installed at top and bottom of each planet gear.
4. Install. differential mainshaft gear.

Differential Case Assembly:

5. Align and position differential top case on bottom case. Align using scribe marks made at disassembly
6. While holding differential case halves together, invert the differential and start the differential case bolts.
7. Tighten differential case bolts to specified torque.