Disassemble

Exploded View Of Transfer Case:

1. Remove fill and drain plugs.
2. Remove front yoke retaining nut, then the yoke and seal. The yoke seal, washer and nut are not reusable and must be discarded at this time.
3. Shift transfer case control lever to four-wheel low position.
4. Remove extension housing attaching bolts and the housing. Do not pry housing from case. If necessary, tap housing off with a soft-faced mallet.
5. Remove and discard rear bearing snap ring from mainshaft.
6. Remove rear retainer attaching bolts, then position a screwdriver under each tab on retainer housing and carefully pry retainer from case. Do not pry against sealing surfaces.
7. Remove rear case to front case attaching bolts, then carefully separate the cases using screwdrivers inserted in case slots. Do not pry against sealing surfaces.
8. Remove oil pump and rear case as an assembly.
9. Remove oil pickup screen and tube from oil pump.
10. Separate oil pump from rear case, then remove and discard pickup tube O-ring from oil pump.
11. Disassemble oil pump as follows:
a. Mark relationship between pump housings for assembly reference.
b. Remove attaching screws and separate pump halves.
c. Note position of pump gears for assembly reference, then remove gears from housing.
12. Remove mode spring from mode shaft.
13. Tap front output shaft free from shaft bearing, then remove the shaft and drive chain as an assembly. Lift mainshaft slightly, if necessary, to ease removal.
14. Remove mainshaft and mode fork as an assembly from front case.
15. Remove mode fork and shift rail from synchronizer sleeve.
16. Mark position of synchronizer sleeve for assembly reference, then remove the sleeve from mainshaft.
17. Remove and discard synchronizer hub snap ring.
18. Remove synchronizer hub and snap ring, then the drive sprocket from mainshaft.
19. Slide range fork pin out of slot in sector, then remove range fork and shift hub as an assembly, noting position for assembly reference.
20. Remove range lever from sector shaft.
21. Remove shift sector, then the sector shaft bushing and O-ring.
22. Remove shift detent pin, spring and plug from case.
23. Invert front case and remove front bearing retainer attaching bolts.
24. Carefully pry front bearing retainer from front case using suitable screwdriver positioned into slots cast in retainer.
25. Remove input gear snap ring, then press input and low range gear assembly from input gear bearing using a suitable press.
26. Remove snap ring, then the input gear retainer, thrust washers and input gear from low range gear. The low range annulus gear is not serviceable. If the gear is damaged, the gear and front case must be replaced as an assembly.
27. Remove and discard oil seals from rear retainer, rear extension housing, oil pump feed housing and case halves.
28. Remove magnet from front case.