NV233 Transfer Case - Disassembly

DISASSEMBLY




NV233 Exploded View





Position transfer case on shallow drain pan. Remove drain plug and drain lubricant remaining in case.

REAR RETAINER AND OIL PUMP










1. Remove extension housing bolts.
2. Tap extension housing (1) with plastic or soft faced mallet (2) to loosen sealer.










3. Separate extension housing from rear retainer.
4. Remove rear bearing snap-ring.










5. Remove bolts holding rear retainer to rear case half.
6. Loosen rear retainer (1) with pry tool (3) to break sealer bead. Pry only against retainer boss as shown.

SHIFT MOTOR ASSEMBLY










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 from the transfer case.

FRONT OUTPUT SHAFT SEAL





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





2. Remove the front propeller shaft seal boot (2) from the front output shaft seal slinger (3).





3. Using a suitable hammer and chisel, strike the seal slinger (2) with the chisel as shown in three, equally spaced locations.

NOTE: The indentations (2) should appear as shown here.





4. Remove the seal slinger (1) from the front output shaft.





5. Remove the front output shaft seal slinger (1) from the output shaft (2).





6. Remove the front output shaft seal (1) from the transfer case bore (2) using a suitable tool or a screw mounted in a slide hammer.
7. Remove front output shaft snap ring.

FRONT OUTPUT SHAFT AND DRIVE CHAIN










1. Support transfer case so rear case is facing upward.
2. Remove bolts holding front case to rear case. The case alignment bolts require flat washers (1).










NOTE: Insert pry tool blade only into notches provided at each end of case.

3. Loosen rear case (1) with flat blade pry tool (2) to break sealer bead.
4. Remove rear case from front case.










5. Disengage oil pickup tube from oil pump (1) and remove oil pump assembly.
6. Remove pick-up tube o-ring (2) from oil pump (1), if necessary. Do not disassemble the oil pump, it is not serviceable.
7. Remove the magnet from the magnet pocket.










8. Remove oil pickup tube (3) from rear case.










9. Remove mode fork spring (1).





10. Remove the front output shaft, mainshaft and chain assembly as one.

SHIFT FORKS AND MAINSHAFT










1. Remove detent plug (3), O-ring (2), detent spring (4), and detent plunger (1).










2. Remove mode fork (2) and sleeve (1) as an assembly. Note position of sleeve for assembly reference. The short side of the sleeve faces upward.










3. Remove range fork (2) and hub (1) as an assembly. Note fork position for installation reference.










4. Remove shift sector (1) from front case.










5. Remove shift sector o-ring (2).

MAINSHAFT










1. Remove mode hub (1) retaining ring (3) with heavy duty snap-ring pliers (2).










2. Slide mode hub (2) off mainshaft (1).










3. Slide drive sprocket (1) off mainshaft (2).

INPUT GEAR AND LOW RANGE GEAR










1. Remove front bearing retainer (2) attaching bolts (3).










2. Remove front bearing retainer. Pry retainer (1) loose with pry tool positioned in slots (2) at each end of retainer.










3. Remove front bearing retainer seal. Tap seal out with drift and hammer.
4. Remove input gear retaining ring (1) with heavy duty snap-ring pliers (3)










5. Place front case in horizontal position. Then remove input gear and low range gear as an assembly (1). Tap gear out of bearing with plastic mallet if necessary.

INPUT AND LOW RANGE GEAR










1. Remove snap-ring (1) that retains input gear in low range gear.










2. Remove retainer (3) from the low range gear.










3. Remove front tabbed thrust washer (1).










4. Remove input gear (1).










5. Remove rear tabbed thrust washer from low range gear.