Model 207

Transfer Case Model 207 Disassembly

Clean

- The transfer case exterior using a solvent and a stiff brush.

Remove or Disconnect

Figure 19- New Process 207 Transfer Case:

Figure 20- New Process 207 Transfer Case:

Figure 21- Extension Housing Removal:

Figure 22- Rear Output Bearing Retaining Ring Removal:

Figure 23- Rear Retainer Removal:

Figure 24- Rear Housing Removal:

Figure 25- Shift Shaft Removal:

Figure 26- Main Drive Shaft Removal:

Figure 27- Planetary Gear And Range Fork Removal:

Figure 28- Input Gear And Bearing Removal:

Figure 29- Shift Sector Removal:

Figure 30- Low Range Lock Plate Removal:

Figure 31- Input Gear Pilot Bearing Removal:

Figure 32- Input Gear Front Bearing Removal:

Figure 33- Front Output Shaft Rear Bearing Removal:

Figure 34- Front Output Shaft Front Bearing Retainer Ring Removal:

Tools Required:

J-8092 Driver Handle
J-29369-1 Input Gear Pilot Bearing Remover
J-29369-2 Front Output Shaft Rear Bearing Remover
J-33367 Bearing Cup Puller Bridge
J-33826 Rear Output Bushing Installer and Mainshaft Sprocket Bearing Remover
J-33839 Rear Output Bushing Remover
J-33841 Input Driver Gear Roller Bearing Remover

1. Fill plug (16) and drain plug.
2. Yoke nut (49). Discard the nut.
3. Yoke (48).
4. Yoke seal washer (50). Discard the washer.
- Position the transfer case on end.
- Position the front case on wood blocks.
- Shift the transfer case to 4 Lo.
5. Extension housing attaching bolts (13).
- Tap the shoulder with a soft hammer on the extension housing to break the sealer loose.
6. Extension housing (12).
7. Snap ring (11) for the rear bearing (10) from the mainshaft (1). Discard the snap ring.
8. Rear retainer attaching bolts (9).
- Using a hammer, tap the shoulder on the retainer to break the sealer loose.
9. Rear retainer (7) from the case.
10. Pump housing (4) from the case.
11. Pump seal (3) from the pump housing (4). Discard the seal.
12. Case halves retaining bolts (17).
13. Rear case (2) from the front case (44).
- Insert screwdrivers into the slots casted in the case ends. Pry upward.
14. Front output shaft (21) and drive chain (76) as an assembly.
- Raise the mainshaft slightly for the output shaft to clear the case.
15. Mode fork shaft (73) from the transfer case.
- Pull up on the shaft until the shaft clears the range fork.
- Rotate the mode fork and shaft and remove the assembly from the transfer case.
16. Main drive shaft (1).
- Pull up on the drive shaft until it separates from the planetary assembly.
- Remove the drive shaft from the transfer case.
17. Planetary assembly with the range shift fork (66) from the transfer case (2).
18. Main drive gear thrust washer (34).
19. Main drive gear (37).
20. Input gear thrust bearing (38).
21. Front thrust washer (39).
22. Shift sector detent spring retaining screw (55).
23. Shift sector detent spring (61).
24. Nut (60).
25. Shift shaft lever (59).
26. Retainer (58).
27. Seal (57).
28. Shift sector (74).
29. Spacer (75).
30. Locking plate retaining bolts (47).
31. Lock plate (40).
32. Input gear pilot bearing (35), using J-29369-1 with a slide hammer.
33. Front output shaft seal (52).
34. Input gear seal (46).
35. Rear extension seal (15).
36. Input drive gear caged roller bearings (45).
- Use J-33841 with J-8092. Press out the bearings.
37. Front output shaft rear bearing (20).
- Use J-29369-2 with J-33367.
38. Rear mainshaft bearing (10) from the rear retainer (7) using a hammer and a drift.
39. Front output shaft bearing retaining snap ring (53), using a screwdriver.
40. Front output shaft bearing (54), using a hammer and drift.
41. Extension housing bushing (14).
- Use J-33839 with J-8092. Press the bushing out.