Disassembly

DISASSEMBLY





Position transfer case in a shallow drain pan. Remove drain plug (1) and drain any remaining lubricant remaining in case.

SHIFT MOTOR ASSEMBLY AND FRONT OUTPUT SHAFT SEAL






1. Remove the transfer case isolator gasket (1) from the transfer case (2).




2. Remove the front output shaft speed sensor (1) from the front case (2).




3. Remove the front propeller shaft seal boot (1) retaining clamp (2).




4. Remove the front propeller shaft seal boot (1).




5. Remove the front output shaft seal slinger (1) by bending (2) the slinger ears away from the transfer case.




6. Using a suitable pry tool (2), remove the slinger (1) from the output shaft using care not to damage the shaft.




7. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) to the transfer case.




8. Remove the shift motor and mode sensor assembly (1) from the transfer case.




9. Remove the shift motor isolator (1) from the transfer case (2).




10. Using a screw and a slide hammer, remove the front output shaft seal (1) from the transfer case (2).


OIL PUMP AND REAR CASE






1. Remove the rear output shaft speed sensor (1) from the transfer case (2).




2. Remove the rear output seal (1) from the rear case half (2).




3. Remove rear case (1)-to-front case (2) bolts (3).




4. Remove the access plug (1) in the rear case half (2).




5. Through the access hole (1) in the rear case half (2), release the output shaft bearing from the rear case with a suitable pair of snap-ring pliers.




6. Separate the rear case from the front case by gently prying the case apart at the locations provided.
7. Remove the rear case (1) from the front case (2).




8. Remove the rear output shaft bearing (3) retaining ring (2) from the output shaft (1).




9. Remove the rear output shaft bearing (1) from the output shaft (2).




10. Remove the wave washer (1) from the output shaft (2).




11. Remove the output shaft tone wheel (1) from the output shaft (2).




12. Disengage the oil pump pick-up tube (2) from the oil pump (1).




13. Remove the oil pump (1) from the output shaft (2).


DRIVE CHAIN, SPROCKETS, AND MAINSHAFT






1. Remove front sprocket (1) retaining ring (2).




2. Remove the mainshaft drive sprocket (1) retaining ring (2) from the mainshaft.




3. Remove the mainshaft drive sprocket (1), front drive sprocket (3), and chain (2) as assembly.




4. Remove the mainshaft and clutch assembly (1) from the transfer case.




5. Remove the oil pump pick-up tube (1) from the transfer case (2).


SHIFT COMPONENTS






1. Loosen the clutch lever pivot bolt (1) in the front case (2).




2. Remove the pivot bolt (1) from the transfer case (2).




3. Remove the clutch lever (1) from the transfer case (2).




4. Remove the shift rail (1) from the range fork assembly (2).




5. Remove the range sleeve (1) and range fork assembly from the transfer case.




6. Remove the snap-ring that holds the shift sector into the transfer case.
7. Remove the shift sector (1) from the transfer case (2).


FRONT OUTPUT SHAFT






1. Remove the retaining ring (1) from the front output shaft (2).




2. Remove the front output shaft (1) from the bearing in the front case (2).


INPUT AND PLANETARY GEAR






1. Remove the input gear seal (1) from the front case (3) with suitable screw and slide hammer.




2. Remove input gear (1) retaining ring (2) with heavy duty snap-ring pliers.




3. Remove input gear and low range gear as an assembly (2). Tap gear out of bearing with plastic mallet, if necessary.