Remove

Figure 2:

Figure 3:

REMOVE (Figures 2 & 3)

Tools required:
J8092 Drive handle
J33790 Bearing installer and remover

1. Transfer case from vehicle.

- Refer to Section 7D of the appropriate S/T Service Manual for complete transfer case removal procedure.

2. Front output flange nut (77), washer (76), rubber sealing washer (75) and front output flange
(74) from the front output shaft.

3. Vacuum switch (46) and O-ring seal (47).

4. Poppet screw (68), O-ring seal (69), poppet spring (71) and poppet plunger (70).

Mainshaft Extension and Oil Pump Housing

5. Rear extension housing bolts (3) and rear extension (4).

6. Bearing retainer (snap ring) (5) from the mainshaft (19).

7. Pump retainer housing bolts (7).

8. Pump retainer housing (8) from the rear case half (17).

9. Speedometer tone wheel (11) from the mainshaft (19).

10. Case bolts (3) from the case halves.

- Note the two longer bolts (16) and washers go into doweled case holes (33).

- Separate case halves, insert screwdrivers into the slot cast in the case ends and pry apart. Do not attempt to wedge the case halves apart at any point on the mating surfaces.

- Be careful not to damage the oil pump (12) (located in the rear case half) while removing the rear case half (17).

Internal Components

11. Fork shift spring (52).

12. Mainshaft (19)/drive sprocket 14071703 (20), chain (58) and front output shaft (21) as a unit. Mode shift fork (54) and shift rail (48) will be removed with the mainshaft.

INSPECT: The teeth of the synchronizer stop ring (28) and drive sprocket (20) for damage. If they are damaged, or in cases of customer complaint of clash when shifting from 2Hi to 4Hi, follow steps 13, 14 & 15, otherwise skip to step 16.

13. Retainer (snag ring) (83) from the mainshaft (19).

14. Synchronizer assembly (81).


15. Drive sprocket (20) from the mainshaft (19).

16. Range shift fork (51), range shift hub (34) and sector with shaft (55) from the planetary carrier (36).

- It is necessary to rotate the sector with shaft (55) to obtain clearance when removing the range fork (51).

17. Plastic washer (retainer) (66) and O-ring seal (67) from the front case half.

IMPORTANT: Group B vehicles should complete step 17 and skip to INSTALL step 8.

18. Input bearing retainer bolts (43) and input bearing retainer (44) from the front case half (45).

19. Retainer snap ring from the input gear (38).

20. Planetary carrier (36) and the input gear (38) from the annulus gear (62) using a soft hammer.

21. Input bearing retainer (39) and input bearing (40).

22. Front output bearing retainer ring (snap ring) (60).

23. Front output bearing (61) from the front case half (45) using J33790, and J8092.

24. Seal (42) from the input bearing retainer (44) if it shows signs of damage.