1. Transfer Case Disassemble
Transfer Case Disassemble^ Tools Required
- J 22912-01 Split-Plate Bearing Puller
- J 23907 Slide Hammer with Bearing Adapter
- J 26941 Bushing and Bearing Remover - 3-4 inch
- J 45380 Transfer Case Rear Bushing Remover and Installer
Important:
^ The following service procedure will cover light duty, heavy duty, and super duty versions of this transfer case.
^ The front output shaft seal and the input shaft seal only require replacement if faulty, or if removing the front output shaft or input gear.
1. Remove the rear output shaft seal.
2. Inspect the rear output shaft bushing for scoring or wear.
3. Remove the rear output shaft bushing using the J 45380.
^ Install the finger section of the J 45380 in front of the bushing.
^ Install the tube and forcing screw assembly to the finger section. Ensure the forcing screw is backed out.
^ Using a wrench on the forcing screw, remove the rear output shaft bushing.
4. Remove the access hole plug.
5. Remove the transfer case vehicle speed sensor.
6. Remove the encoder motor assembly.
7. Remove the vent tube ONLY if the vent tube elbow is damaged.
8. Remove the transfer case retaining bolts, the washers, and the brackets.
9. Mark the location of the brackets for correct assembly.
10. Insert a screwdriver into the slot on the left side of the transfer case.
11. Insert a screwdriver into the slot on the right side of the transfer case.
12. With equal pressure applied on each screwdriver, separate the front half and the rear half.
13. Using a pair of snap ring pliers, release the outside retaining ring for the rear output shaft bearing.
14. Remove the rear case half from the front case half.
15. Remove the rear output shaft bearing retaining ring.
16. Remove the rear output shaft bearing.
Important: The super duty version of the NVG 263 transfer case does not use a retaining ring for the speed reluctor wheel.
17. Remove the speed reluctor wheel retaining ring.
18. Remove the speed reluctor wheel.
19. Remove the oil pump suction pipe from the oil pump assembly.
20. Remove the oil pump screen from the front case half.
21. Disconnect the connector between the oil pump suction pipe to the oil pump screen.
22. Remove the magnet.
23. Remove the oil pump assembly.
24. Remove the O-ring seal for the oil pump suction pipe.
Important: The super duty version of the NVG 263 transfer case does not use an oil pump seal.
25. Remove the O-ring seal for the oil pump.
26. Remove the shift fork shaft detent spring.
27. Remove the driven sprocket retaining ring.
28. Remove the drive sprocket retaining ring.
Important: If the drive chain and sprockets are to be reused, mark the position drive chain to the drive sprockets in order to ensure that any wear patterns will be matched for proper installation.
29. Remove the drive chain and the sprockets from the mainshaft and the front output shaft.
30. Remove the two/four wheel drive synchronizer gear from the drive sprocket sleeve.
Important: Remove the rear output shaft as an assembly with the synchronizer and the shift fork.
31. Remove the rear output shaft with the shift fork.
The shift shaft can remain in the case.
32. Remove the two/four wheel drive mode shift fork from the synchronizer assembly.
33. Mount the rear output shaft in a soft-jaw vise with the input end up.
34. Remove the synchronizer assembly retaining ring.
35. Remove the synchronizer as an assembly.
36. Remove the synchronizer outer ring, middle ring, and inner ring.
37. Remove the shift detent spring bolt.
38. Remove the shift detent spring and the plunger.
39. Remove the shift shaft from the high/low range fork and the front case.
40. Remove the high/low range collar and the shift fork.
41. Remove the range collar from the shift fork.
42. Remove the front retaining ring for the drive sprocket from the drive sprocket sleeve.
43. Remove the drive sprocket sleeve from the rear output shaft.
44. If necessary, disassemble the synchronizer assembly.
^ Remove the inner ring (1)
^ Remove the middle ring (2)
^ Remove the outer ring (3)
^ Remove the synchronizer sleeve (4) from the hub (6)
^ Remove both insert springs (5 and 8) from the hub.
^ Remove the inserts (7).
45. Disassemble the range fork assembly, if necessary, for inspection.
46. Remove the front input shaft seal.
47. Remove the outer retaining ring for the input gear bearing.
48. Remove the high/low planetary carrier.
49. Remove the retaining ring for the input gear.
50. Remove the planetary carrier lock plate.
51. Remove the planetary carrier front thrust washer.
52. Remove the input gear,
53. Remove the planetary carrier rear thrust washers.
54. Inspect the needle bearing in the input gear for being faulty.
55. Remove the needle bearing and the cup plug from the input gear using a brass drift and a hammer, if faulty.
Important: For the super duty version of the NVG 263, it may be necessary to rotate the bearing in the front case in order to gain access to the retaining ring.
When removing the retaining ring for the input shaft bearing in the super heavy duty version of the NVG 263, the retaining ring must be fully expanded and then remove the input shaft bearing. DO NOT release the retaining ring until the input shaft bearing has been removed.
56. Remove the input gear bearing retaining ring.
57. Remove input gear bearing.
Notice: Refer to Transfer Case Seal Removal Notice in Service Precautions.
58. Insert a flat-tipped screw driver in the inner race.
59. Pry the inner race back.
60. Insert a small pry bar in the inner race.
61. Remove the inner race from the seal.
62. Insert a flat-tipped screw driver or a small pry bar between the lip of the outer lip of the front output shaft seal and the transfer case.
63. Remove the remaining part of the front output shaft from the transfer case.
64. Remove the front output shaft front bearing retaining ring.
65. Remove the front output shaft assembly.
66. Inspect the rear bearing race on the front output shaft for being faulty.
67. Remove the bearing race using a hydraulic press and J 22912-0 1.
68. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.
69. Remove the front output shaft front bearing inner retaining ring.
70. Remove the front output shaft front bearing.
71. Inspect the front output shaft rear bearing for being faulty.
72. If the bearing is faulty, remove the bearing using the J 23907 (2) and the J 26941 (1).
73. Remove the shift detent lever retaining ring.
74. Remove the shift detent lever shaft.
75. Inspect the shift detent lever bearing and seal for being faulty.
76. If the seal or bearing is faulty, remove the bearing from the case.