Steps 45 - 78

Transfer Case Disassemble Con't





41. Remove the clutch apply plate.





42. Remove the clutch spring.





43. Remove the clutch hub retaining ring.





44. Remove the clutch housing assembly.





45. Hold on to the clutch plates, and turn the clutch housing over on a work bench.
46. Remove the clutch housing from the clutch plates and the clutch hub.
47. Remove the clutch hub from the clutch plates.





48. Remove the drive sprocket retaining ring from the clutch housing.





49. Remove the drive sprocket from the clutch housing.





50. Remove the clutch housing retaining ring from the rear output shaft.





51. Remove the rear output shaft rear thrust washer.





52. Using a press, remove the planetary gear assembly.
52.1. Support the front case half on press plates, to allow the planetary gear assembly removal.
52.2. Use a suitable adapter to press on the input gear bearing.





53. Using a press, remove the input gear bearing.
53.1. Support the planetary gear assembly on press plates, to allow removal of the input gear.
53.2. Use a suitable adapter to press on the input gear.





54. Remove the input gear.





55. Remove the planetary gear large diameter thrust washer.





56. Remove the input gear smaller diameter thrust washer.





57. If necessary, remove the bore seal and the input gear thrust bearing from the input gear.





58. Remove the driven gear retaining ring from the front output shaft.
59. Remove the driven gear from the front output shaft.





60. Using a hydraulic press and a suitable adapter on the front input shaft, remove the front speed sensor reluctor wheel.





Important: The vent only requires removal if it is damaged.

61. Remove the vent.





62. Remove the front output shaft VSS and O-ring seal from the rear case.





63. Remove the chip collector magnet from the rear case.





64. Remove the oil pump suction pipe with the oil pump screen.





65. Remove the retaining ring for the control actuator lever shaft.
66. Discard the retaining ring.





67. Remove the control actuator lever shaft from the rear case.





Important: Only remove the bearings if they are faulty. Do not reuse the bearings.

68. Inspect the front output shaft rear bearing for being faulty.
69. Using the J 23907 (1) and the J 26941 (2), remove the rear bearing for the front output shaft.





Important: Only remove the bearings if they are faulty. Do not reuse the bearings.

70. Inspect the rear output shaft bearing for being faulty.

Important: The bushing surface for the oil pump is located by the output shaft bearing. When using the J 26941, the jaws must not come in contact with the oil pump bushing surface.

71. Using the J 23907 (1) and the J 26941 (2), remove the rear output shaft bearing from the rear case. Ensure the jaws on the J26941 are between the bearing and the oil pump bushing.





Important: Only remove the bearings if they are faulty. Do not reuse the bearings.

72. Inspect the control actuator lever shaft bearing for being faulty.
73. Using the J 44707 (2) and the J 44737 (1), remove the control actuator lever shaft bearing.





Notice: Refer to Transfer Case Seal Removal Notice in Service Precautions.

74. Using a suitable prying tool, remove the front output shaft seal.
75. Discard the seal.





Important: Only remove the bearings if they are faulty. Do not reuse the bearings.

76. Inspect the front output shaft front bearing for being faulty.
77. Using a hammer and a punch, remove the front bearing for the front output shaft from the front case.
78. Clean and inspect all the internal parts of the transfer case.