NV146 Transfer Case - Disassembly

DISASSEMBLY










1. Place the transfer case in a shallow pan and remove the fill (1) and drain (2) plugs to drain the remainder of the fluid.





2. Using Holder C-3281 (1), remove the rear flange (2) nut.





3. Remove the rear output flange (1) from the main shaft (2). If necessary, use a suitable 2 or 3 jaw puller to remove the output flange.





4. Remove the bolts (1) holding the shift motor (2) to the transfer case.





5. Remove the shift motor (1) from the shift sector (2) and the transfer case (3).





6. Remove the bolts (3) holding the rear cover (2) onto the rear housing (1).






NOTE: Use the pry slots provided and take care not to damage the sealing surface.

7. Remove the rear cover (1) from the rear housing (2).





8. Remove the oil pump inner rotor (2) from the main shaft (1) and rear housing (3).





9. Remove the oil pump outer rotor (2) from the main shaft (1) and rear housing (3).





10. Remove the bolts (2) holding the rear housing (1) to the front housing (3).






NOTE: Some prying may be necessary to break the seal between the front and rear case. Use care to not damage the sealing surfaces.

11. Remove the rear housing (1) from the front housing (2).





12. Remove the thrust bearing support plate retaining ring (2) from the main shaft (1).





13. Remove the thrust bearing support plate (2) from the main shaft (1).





14. Remove the thrust bearing (2) from the main shaft (1).





15. Remove the clutch pressure plate (2) from the main shaft (1) and clutch assembly.





16. Remove the wave spring (2) from the main shaft (1).










17. Remove the inner hub (2), friction discs, and steel plates as one.





18. Remove the snap-ring (2) holding the clutch drum/drive sprocket assembly to the mainshaft.





19. Remove the front drive sprocket retaining ring (2) from the front output shaft (1).





20. Remove the front drive sprocket (3), clutch drum/mainshaft drive sprocket (1), and drive chain (2) as one.
21. Remove the mainshaft from the input bearing.





22. Remove the screws (2) holding the chain guide rails (3) to the front housing (1).





23. Remove the drive chain guide (1) from the transfer case.





24. Remove the clutch lever rail plug (1) from the rear housing.





25. Remove the clutch lever rail (2) from the rear housing (1).





26. Remove the clutch lever assembly (1) from the rear housing.





27. Remove the oil pick-up tube and screen (1) from the rear housing.





28. Remove the oil pick-up tube o-ring (2) from the rear housing (1).





29. Remove the retaining ring (2) from the shift sector shaft (1).





30. Remove the shift sector (2) from the rear housing (1).










31. Remove the retaining ring (2) from the front output shaft (1).










32. Remove the front output shaft assembly (2) from the front case (1) and the front output shaft front bearing.
33. Remove the front output shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
34. Remove the input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.