Transfer Case Disassemble

Transfer Case Disassemble

^ Tools Required
- J 2619-01 Slide Hammer
- J 22912-01 Split-Plate Bearing Puller
- J 23907 Slide Hammer with Bearing Adapter
- J 26941 Bushing and Bearing Remover - 3-4 in
- J 45380 Transfer Case Rear Bushing Remover and Installer
- J 45548 Mainshaft Support Bushing/Bearing Remover





1. Remove the access plug from the transfer case.





2. Remove the transfer case vehicle speed sensor.





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

3. Remove the input shaft seal.





4. Remove the rear output shaft seal.





5. Inspect the rear output shaft bushing for scoring or wear.
6. Using the J 45380, remove the rear output shaft bushing.
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.





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

7. Insert a flat-tipped screw driver in the inner race.
8. Pry the inner race back.





9. Insert a small pry bar in the inner race.





10. Remove the inner race from the seal.





11. 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.





12. Remove the remaining part of the front output shaft from the transfer case.





Important: Mark the location of the brackets.

13. Remove the transfer case bolts, washers, and brackets.





14. Insert a flat bladed screw driver in the slot on the left side of the transfer case.





15. Insert a flat bladed screw driver in the slot on the right side if the transfer case.
16. With equal pressure, press down on the screw drivers.





17. Insert a pair of snap ring pliers into the slot.
18. Using the snap ring pliers, open the outer rear output shaft bearing retaining ring.





19. Remove the rear case half from the front case half.





20. Remove the oil pump screen assembly.





21. Remove the rear output shaft assembly. Hold the planetary carrier in place to prevent removing it with the rear output shaft.





22. Remove the rear output shaft bearing retaining ring.





23. Using the flat side of the J 22912-01 and a press, remove the rear output shaft bearing.





Important: Move the oil pump retaining ring down and away from the tone wheel. This will ensure that the J 22912-01 will not get caught on the retaining ring.

24. Using the J22912-01 and a press, remove the speed reluctor wheel.
25. Discard the speed reluctor wheel after removal.





26. Remove the oil pump retaining ring.





27. Remove the oil pump assembly.





28. Using a flat bladed screwdriver, unseat the annulus retaining ring.





29. Remove the annulus gear retaining ring.





30. Remove the rear output shaft.





31. Inspect the mainshaft rear bearing in the rear output shaft for being faulty.





32. Using the J 2619-01 (1) and the J 45548 (2), remove the mainshaft rear bearing.
33. Remove the planetary carrier assembly. Tap on the end of the mainshaft with a soft-face hammer while lifting off the planetary carrier. A spring style retaining ring holds the planetary carrier to the mainshaft.





34. Remove the planetary carrier assembly thrust washer.





35. Remove the sun gear.





36. Remove the carrier retaining ring.





37. Remove the mainshaft.





38. Remove the planetary carrier sun gear bearing.





39. Remove the driven sprocket retaining ring.





40. Remove the drive chain assembly.





41. Remove the viscous coupling.





42. Using a flat bladed screwdriver, remove the input gear bearing retaining ring from the groove.





43. Remove the input gear bearing retaining ring.





44. Remove the input gear assembly.





45. Remove the input gear bearing retaining ring.





46. Using a press, remove the input bearing.





47. Remove the front output shaft bearing retaining ring.





48. Remove the front output shaft assembly.





49. Remove the front output shaft bearing retainer ring.





50. Remove the front output shaft bearing.





51. Inspect the front output shaft rear bearing race.
52. Using a press and the J 22912-01, remove the front output shaft rear bearing race.





53. Inspect the front output shaft rear bearing.
54. Using the J 23907 (2) and the J 26941 (1), remove the front output shaft bearing from the rear case.