Part 1

DISASSEMBLY

Special Tools:









Figure 1 - MP1522 EXPLODED VIEW








Figure 2 - MP1522 TRANSFER CASE





1. Place the transfer case in a shallow pan and remove the fill (4) and drain (2) plugs to drain the remainder of the fluid.




Figure 3 - REAR OUTPUT FLANGE NUT





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




Figure 4 - OUTPUT FLANGE O-RING





4. Remove the rear output flange o-ring from the rear output flange.










5. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) to the transfer case.










6. Remove the shift motor and mode sensor assembly (1) from the shift rail (2) and the transfer case (3).




Figure 7 - SHIFT MOTOR SEAL RING





7. Remove the seal ring (1) from the shift motor (2).




Figure 8 - DAMPER





8. Remove damper bolts (2) and damper (1), (if equipped).




Figure 9 - REAR RETAINER





9. 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.

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




Figure 11 - DETENT ASSEMBLY





11. Remove the detent assembly (1) from the rear housing (2).










NOTE: Rotate the sector downward to ease the removal of the roll-pin.

12. Using a suitable punch, remove the roll-pin (2) holding the sector roller (4) to the shift rail (3).










13. Remove the sector roller (1) from the shift rail (2).










14. Remove the anti-rotation bracket (1) from the shift rail (2).










15. 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.

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










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










18. Remove the sector shaft (2) from the rear housing (1).




Figure 19 - OIL PUMP ASSEMBLY





19. Remove the oil pump (2) and oil pump tube (1) from the mainshaft.




Figure 20 - OIL TUBE O-RING





20. Remove the o-ring seal (2) from the oil tube (1).




Figure 21 - MAGNET