Part 2

DISASSEMBLY

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

SHIFT FORKS AND MAINSHAFT










1. Shift transfer case into NEUTRAL.
2. Remove nut that retains the shift lever to sector shaft. Then remove shift lever (3) and spacer from the shaft.
3. Remove the sector support (2) with Socket 9033.










4. Remove the transfer case position sensor or switch (2) from the front case half (1).










5. Loosen detent plug (2).










6. Remove detent plug (2), spring (3), and plunger (4). Note that the plug has an O-ring seal. Remove and discard this seal.










7. Using a screw mounted in a slide hammer, remove the front output shaft seal.
8. Remove the front output shaft snap-ring (2).










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










10. Pull mainshaft assembly (2) out of input gear, mode sleeve, and case.










11. Remove mode fork (2), mode sleeve (3), and shift rail (1) as assembly. 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).










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










13. Remove shift sector (1).

MAINSHAFT










1. Remove the clutch gear (2) from the output shaft (1).










2. Remove the mode hub retaining ring (3) from the mainshaft (1).










3. Remove the mode hub (2) from the mainshaft (1).










4. Remove the drive sprocket drive hub (2) from the mainshaft.

INPUT AND PLANETARY GEAR










1. Remove input gear seal with suitable screw and slide hammer.
2. Remove 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.










4. Remove snap-ring (2) that retains input gear in the low range gear (1).










5. Remove retainer (2).










6. Remove front thrust plate (2) from the input gear (1).










7. Remove input gear (1) from the low range planetary (2).










8. Remove bottom tabbed thrust washer (2) from low range planetary (1).