Electronic Shift

1. Drain fluid from transfer case.
2. Remove front and rear output shaft yokes by removing locknut, flat steel washer and rubber seal from the output shaft.
3. Remove rear output shaft.
4. Remove wire connector assembly from mounting bracket on rear cover.
5. Remove four wheel drive indicator and switch and washer.
6. Remove locking sleeve from wire connector.
7. Remove brown wire from the No. 1 center position in the connector.

Fig. 40 Removing Rear Bearing Retainer:

Fig. 41 Removing Speed Sensor And Speedometer Gear:

8. Remove four No. 50 Torx head attaching bolts securing rear bearing retainer to cover, Fig. 40. Pry rear bearing retainer from cover
9. Lift rear output shaft and remove speedometer gear attaching clip.
10. Slide speedometer gear forward and remove ball with a magnet.
11. Remove speedometer gear.
12. Remove speed sensor from rear cover, Fig. 41.
13. Remove three bolts attaching shift motor to rear cover. Remove shift motor.
14. Remove output shaft snap ring retaining upper rear ball bearing.
15. Remove twelve No. 50 Torx head attaching bolts attaching front case to rear cover, then separate front case from rear cover.
16. Remove front output shaft needle bearing from rear cover.

Fig. 42 Rear Cover Assembly:

Fig. 43 Removing Clutch Housing Snap Ring:

Fig. 44 Remove Mode Shift Fork And Shift Coller:

17. Remove rear output shaft bearing from inside of case, Fig. 42.
18. Remove nuts attaching clutch coil assembly from rear cover. Pull assembly, along with O-rings and brown wire, from cover.
19. Remove shift shaft bushing and seal from rear cover.
20. Remove snap ring from output shaft attaching clutch housing, Fig. 43.
21. Remove spring from shift shaft and lift mode shift fork complete with shift collar from upper rear output shaft sprocket splines, Fig. 44.
22. Disassemble the 2W-4W lock-up assembly by removing internal snap ring, then pull the lock-up hub and spring from the collar.
23. Remove snap ring attaching the lower sprocket to the lower output shaft. Grasp the upper and lower sprocket complete with the chain, then lift them out at the same time from upper and lower output shafts.
24. Remove shift rail by sliding it straight out of shift fork.
25. Remove high/low shift fork by first rotating it until the roller is free from the cam, then sliding out of engagement from the shifting hub.
26. Remove helical cam assembly from front case. If it is necessary to disassemble the helical cam assembly, care should be taken as the cam is slid rearward to disengage it from the spring. The spring is energized and can release violently. The spring must be removed from the helical cam and the shaft finger. Do not get hands in the way when disengaging the spring. It will rotate to the point that the spring ends will be approximately 180° apart.
27. Remove chip collecting magnet from case slot.
28. Lift pump screen, then remove output shaft assembly with pump.
29. Remove high/low shift hub.
30. Remove front output shaft from front case.
31. Turn front case over and remove front oil seal from case.
32. Reaching through front opening of case, expand snap ring on input snap and carrier assembly allowing it to drop out of the bearing. The carrier assembly, including the input shaft, is serviced as an assembly only. If the needle bearing or bushing is replaced, drive out both of them through the input shaft splines.
33. Remove ring gear internal snap ring, then lift ring gear out.
34. Remove front input shaft bearing snap ring, then the bearing.