Disassembly
DISASSEMBLY
Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining in case.
SHIFT MOTOR ASSEMBLY AND FRONT OUTPUT SHAFT SEAL
1. Remove the bolts (3) which hold the shift motor and mode sensor assembly (2) to the transfer case (1).
2. Remove the shift motor and mode sensor assembly (2) from the transfer case (1).
3. Remove the front propeller shaft seal boot retaining clamp (2).
4. Remove the front propeller shaft seal boot (1) from the output shaft seal slinger (2).
5. Remove the front output shaft seal slinger (1) by bending the slinger away (2) from the transfer case.
6. Using a suitable pry tool, remove the slinger from the output shaft using care not to damage the shaft.
7. Using a screw and a slide hammer, remove the front output shaft seal.
REAR EXTENSION
1. Remove the rear extension housing (1) bolts.
2. Remove the rear extension housing (1) from the transfer case (2). Tap extension once or twice with a plastic mallet to break sealer bead and loosen it using the supplied pry slots (3).
3. Remove the output bearing retaining ring (3) with heavy duty snap-ring pliers.
OIL PUMP AND REAR CASE
1. Remove the rear case-to-front case bolts (3).
2. Loosen the rear case (1) with pry tool to break sealer bead. Insert tool in slot (3) at each end of case.
3. Unseat the rear case from alignment dowels.
CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft inner bearing race and will become mis-aligned if the bolts are loosened. If the transfer case failure has generated any debris which may have become trapped in the oil pump. the rear case and oil pump assembly MUST be replaced.
4. Remove the rear case (1) and oil pump assembly from front case (2).
5. Remove the oil pump pickup tube.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Remove the shift rail spring (2).
2. Remove the front sprocket retaining ring (2).
3. Remove the mode fork (2) and sleeve (3) from the shift rail (1) and mainshaft.
4. Remove the rear output shaft retaining ring (2) from the output shaft (1).
5. Pull front sprocket (1), rear sprocket (3), and chain (2) outward simultaneously.
6. Remove front sprocket (1), rear sprocket (3), and chain (2) as an assembly.
SHIFT FORKS AND MAINSHAFT
1. Loosen detent plug (2).
2. Remove the detent plug (2), spring(3), and plunger (4). Note that the plug has an O-ring seal. Remove and discard this seal.
3. Remove the front output shaft snap-ring (2).
4. Remove front output shaft (1) from the front output shaft front bearing.
5. Remove the mainshaft and differential assembly (2) from the input gear and transfer case.
6. Remove the shift rail (1) from the range fork assembly (2) and the front case.
7. Remove range fork (2) and hub as an assembly. Note fork position for installation reference.
8. Remove shift sector (1).
9. Remove the shift sector O-ring (2).
MAINSHAFT
1. Remove intermediate clutch shaft snap-ring (1).
2. Remove the intermediate clutch shaft thrust ring (1).
3. Remove the intermediate clutch shaft (1).
4. Remove the differential snap-ring (1).
5. Remove the differential assembly (1) from the mainshaft (2).
6. Remove the mode hub and mode hub retainer (2) from the differential assembly (1).
7. Remove the mode hub retainer (1) from the mode hub (2).
INPUT AND PLANETARY GEAR
1. Remove the input gear seal with suitable screw and slide hammer.
2. Remove the input gear retaining ring (2) with heavy duty snap-ring pliers.
3. Place front case in horizontal position. Then remove input gear and low range gear as an assembly (2). Tap gear out of bearing with plastic mallet, if necessary.
INPUT AND PLANETARY GEAR
1. Remove the snap-ring (1) that retains input gear in low range gear.
2. Remove the retainer (3).
3. Remove the front tabbed thrust washer (1).
4. Remove the input gear (1).
5. Remove the rear tabbed thrust washer (2) from the low range gear (1).