Disassembly

Special Tools:

Special Tools:

Part 1 Of 4:

Part 2 Of 4:

Part 3 Of 4:

Part 4 Of 4:

1. Remove the transfer case .





2. Use the Bench Mounted Holding Fixture to secure the transfer case.





3. Remove the coil wire from the electric shift motor electrical connector.
1 Remove the wire connector spacer.
2 Remove the coil wire connector and pin.
- Use an electrical connector pin extractor tool.





4. Remove the VSS.
1 Remove the bolt.
2 Remove the vehicle speed sensor.





5. Remove the transfer case shift motor.
1 Remove the bolts.
2 Remove the transfer case shift motor.





6. Remove the front output shaft speed sensor.
1 Remove the bolt.
2 Remove the front output shaft speed sensor.





7. Remove the rear output shaft speed sensor.
1 Remove the bolt.
2 Remove the rear output shaft speed sensor.





8. Remove the extension housing shaft seal.
- Use the Impact Slide Hammer and Seal Remover to remove the extension housing seal.





9. Remove the extension housing.
1 Remove the bolts.
2 Remove the extension housing.





10. Remove the speedometer gear spacer.





11. NOTE: When removing the speedometer gear, pry under the metal tone gear to avoid damage to the plastic speedometer gear.

Remove the speedometer drive gear.
1 Slide the speedometer gear down towards the transfer case.
2 Remove the steel ball.
3 Remove the output shaft tone wheel and speedometer gear.





12. NOTE: Lift up on the output shaft while removing the snap ring.

Remove the output shaft snap ring.





13. NOTE: The transfer case cover to case bolts are self-tapping, and it is normal to find metal shavings while removing the cover.

Remove the 20 transfer case cover bolts.





14. Separate the transfer case halves.
- Use pry bosses to separate the case halves.





15. Remove the coil
1 Remove the nuts.
2 Remove the coil.





16. Use the Slide Hammer and Bearing Cup Remover to remove the front output shaft bearing.





17. Use the Slide Hammer and Bearing Cup Remover to remove the rear output shaft bearing.





18. Remove the output shaft thrust bearing snap ring.





19. Remove the thrust bearing assembly.
1 Remove the thick thrust bearing race.
2 Remove the thrust bearing.
3 Remove the thin thrust bearing race.





20. Remove the cam coil housing.





21. Remove the cam assembly.
1 Remove the steel balls.
2 Remove the cam.





22. Remove the wave spring.





23. Remove the clutch pack assembly snap ring.





24. CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold in place. If the thrust washer is not in place, a transfer case clearance problem can occur.

Remove the clutch pack assembly.





25. Remove the front output shaft tone wheel.





26. Remove the thrust bearing assembly.
1 Remove the thrust bearing race.
2 Remove the thrust bearing.
3 Remove the thrust bearing race.





27. Remove the drive chain and sprocket assembly.





28. Remove the lockup hub and lockup shift fork assembly.





29. Remove the magnet from its slot in the case. Clean as needed.





30. Remove the oil pump and output shaft as an assembly.





31. Remove the reduction shift fork and reduction hub assembly.





32. Remove the shift fork shaft.





33. WARNING: DO NOT DISASSEMBLE THE SHIFT CAM ASSEMBLY.

Remove the electric shift cam assembly.





34. Use the Seal Remover to remove the input seal.





35. Remove the planetary gear carrier.
1 Depress the planetary gear carrier snap ring.
2 Remove the front planet.





36. Remove the planetary gearset support bearing.
1 Remove the snap ring.
2 Remove the bearing.





37. Remove the ring gear.
1 Remove the ring gear snap ring.
2 Remove the ring gear.





38. CAUTION: Do not let the front output shaft fall while removing the snap ring.

Remove the output shaft.
1 Remove the front output shaft snap ring.
2 Remove the front output shaft.





39. Use the Bearing Cup Remover and Slide Hammer to remove the front output shaft seal.





40. Use the Bearing Cup Remover and Slide Hammer to remove the rear output shaft bearing.





41. If necessary, remove the bushing and needle bearing from the front planetary gearset carrier.
- Use the 1-1/4-inch to 1-1/2-inch Collet, Actuator Pin and Slide Hammer from the Blind Hole Puller Set for the bearing.
- Use the 1-inch to 1-1/4-inch Collet, Actuator Pin and Slide Hammer from the Blind Hole Puller Set for the bearing.





42. Remove the planetary gear bearing snap ring.





43. Use the Collet and Slide Hammer from the Blind Hole Puller Set to remove the electric shifter shaft seal.