Disassembly
REMOVAL1. Shift transfer case into 2WD.
2. Raise vehicle.
3. Drain transfer case lubricant.
4. Mark front and rear propeller shafts for alignment reference.
5. Support transmission with jack stand.
6. Remove the transfer case skid plate, if equipped.
7. Disconnect front and rear propeller shafts at transfer case.
8. Disconnect transfer case shift motor and mode sensor wire connectors.
9. Disconnect transfer case vent hose.
10. Support transfer case with transmission jack.
11. Secure transfer case to jack with chains.
12. Remove nuts attaching transfer case to transmission (Fig. 2).
13. Pull transfer case and jack rearward to disengage transfer case.
14. Remove transfer case from under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining in case.
COMPANION FLANGE AND EXTENSION HOUSING
1. Install two bolts 180° apart into the front output shaft companion flange.
2. Place holder over the bolts and against the companion flange (Fig. 3).
3. Remove and discard the front companion flange nut.
4. Remove the companion flange from the front output shaft. It may be necessary to use Flange puller 8992 to remove the companion flange.
5. Use a suitable chisel or pry tool to remove the rear extension housing dust boot (Fig. 4).
6. Use a suitable chisel or pry tool to remove the rear extension housing seal.
7. Remove rear extension bolts (Fig. 5).
8. Remove rear extension housing (Fig. 6). Tap extension once or twice with a plastic mallet to break sealer bead and loosen it.
OIL PUMP AND REAR CASE
1. Disengage the oil pump pick-up tube (Fig. 7) from the oil pump.
NOTE: The oil pump pick-up tube seals to the oil pump with an O-ring. Verify that the O-ring was removed with the tube and is in good condition. Replace the O-ring if necessary.
2. Remove the oil pump (Fig. 8).
3. Remove rear case-to-front case bolts (Fig. 9).
4. Remove the rear output shaft bearing inner snap-ring (Fig. 10) from the output shaft using suitable snap-ring pliers.
5. Remove the rear output shaft bearing inner snap-ring (Fig. 11) from the output shaft.
6. Loosen rear case with pry tool to break sealer bead. Insert tool at each end of case (Fig. 12).
7. Unseat rear case from alignment dowels.
8. Remove the rear case from the front case (Fig. 13).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Remove the oil pick-up tube (Fig. 14) and screen from the front case half.
2. Remove the front output shaft drive sprocket retaining ring (Fig. 15).
3. Remove the rear output shaft drive sprocket retaining ring (Fig. 16).
4. Pull front sprocket (Fig. 17), rear sprocket, and chain upward until clear of the front and rear output shaft sprocket splines.
5. Remove chain and sprockets as an assembly.
SHIFT FORKS AND MAINSHAFT
1. Remove the bolts (Fig. 18) that hold the shift motor assembly to the transfer case.
2. Remove the shift motor assembly (Fig. 19) from the transfer case.
3. Remove the sector support with Socket 9033.
4. Loosen detent plug (Fig. 20).
5. Remove detent plug, spring, and plunger (Fig. 21). Note that the plug has an O-ring seal. Remove and discard this seal.
6. Using a screw mounted in a slide hammer, remove the front output shaft seal.
7. Remove the front output shaft snap-ring (Fig. 22).
8. Remove front output shaft from bearing in case (Fig. 23).
9. Pull mainshaft assembly out of input gear, mode sleeve, and case (Fig. 24).
10. Remove mode fork, mode sleeve, and shift rail as assembly (Fig. 25). Note which way the sleeve fits in the fork (long side of sleeve goes to front or the points on the sleeve teeth go to the rear of case).
11. Remove range fork and hub as an assembly (Fig. 26). Note fork position for installation reference.
12. Remove the shift sector (Fig. 27).
MAINSHAFT
1. Remove the clutch gear (Fig. 28) from the output shaft.
2. Remove the mode hub retaining ring (Fig. 29) from the mainshaft.
3. Remove the mode hub (Fig. 30) from the mainshaft.
4. Remove the drive sprocket drive hub (Fig. 31) from the mainshaft.
INPUT AND PLANETARY GEAR
1. Remove input gear seal with suitable screw and slide hammer.
2. Remove input gear retaining ring (Fig. 32) with heavy duty snap-ring pliers.
3. Place front case in horizontal position. Then remove input gear and low range gear as an assembly (Fig. 33). Tap gear out of bearing with plastic mallet, if necessary.
4. Remove snap-ring that retains input gear in the low range gear (Fig. 34).
5. Remove retainer (Fig. 35).
6. Remove front thrust plate (Fig. 36).
7. Remove input gear (Fig. 37).
8. Remove bottom tabbed thrust washer from low range planetary (Fig. 38).
CLEANING
Clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases and retainers with a scraper and 3M'm all purpose cleaner. Use compressed air to remove solvent residue from oil feed passages in the case halves, retainers, gears, and shafts.
INSPECTION
MAINSHAFT/SPROCKET/HUB INSPECTION
Inspect the splines on the hub and shaft and the teeth on the sprocket. Minor nicks and scratches can be smoothed with an oilstone. However, replace any part that is damaged.
Check the contact surfaces in the sprocket bore and on the mainshaft. Minor nicks and scratches can be smoothed with 320-400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fig. 39). Minor nicks can be dressed off with an oilstone but replace the gear if any teeth are broken, cracked, or chipped. The bearing surface on the gear can be smoothed with 300-400 grit emery cloth if necessary.
Examine the carrier body and pinion gears for wear or damage. Check the pinion gear thrust washers on the pinion pins for damage. The carrier will have to be replaced as an assembly if the body pinion pins, or pinion gears are damaged.
Check the lock ring and both thrust washers for wear or cracks. Replace them if necessary. Also replace the lock retaining ring if bent, distorted, or broken.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork shift rail (Fig. 40). Minor nicks on the shift rail can be smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads (Fig. 41). The mode and range fork pads are serviceable and can be replaced if necessary. Check both of the sleeves for wear or damage, especially on the interior teeth. Replace the sleeves if wear or damage is evident.
REAR EXTENSION HOUSING
Inspect the extension housing seal and bushing. Replace both components if either show any sign of wear or damage.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
Inspect the shaft threads, sprocket teeth, and bearing surfaces. Minor nicks on the teeth can be smoothed with an oilstone. Use 320-400 grit emery to smooth minor scratches on the shaft bearing surfaces. Rough threads on the shaft can be chased if necessary. Replace the shaft if the threads are damaged, bearing surfaces are scored, or if any sprocket teeth are cracked or broken.
Examine the drive chain and shaft bearings. Replace the chain and both sprockets if the chain is stretched, distorted, or if any of the links bind. Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully The gear is only serviced as part of the front case. If the gear is damaged, it will be necessary to replace the gear and front case as an assembly. Do not attempt to remove the gear (Fig. 42)
FRONT AND REAR CASES
Inspect the cases for wear and damage.
Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also make sure the front case mounting studs are in good condition.
Check the front case mounting studs and vent tube. The tube can be secured with Loctite 271 or 680 if loose. The stud threads can be cleaned up with a die if necessary. Also check condition of the fill/ drain plug threads in the rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired with Helicoil stainless steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the pump if any part appears to be worn or damaged. Do not disassemble the pump as individual parts are not available. The pump is only available as a complete assembly. The pickup screen, hose, and tube are the only serviceable parts and are available separately.