Disassembly

Special Tools:

Part 2 Of 2:

1. Remove the transfer case.

WARNING: MAKE SURE THE LOCK PIN ON THE BENCH-MOUNTED HOLDING FIXTURE IS SECURE.

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

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 electrical connector pin extractor tool.

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

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

6. Remove the rear output shaft speed sensor bolt, and remove the rear output shaft speed sensor.

7. Use the Companion Flange Holding Tool to remove the transfer case rear driveshaft flange nut.

8. Mark the rear transfer case flange and the rear output shaft for correct assembly.

9. Remove the rear transfer case flange.
1 Remove the nut.
2 Remove the washer.
3 Remove the rubber seal.
4 Remove the rear transfer case flange.

10. Use the Seal Remover to remove the rear transfer case flange seal.

11. Remove the spacer.

12. NOTE: Inspect the rear tone wheel; if teeth are damaged, replace the tone wheel.

Remove the rear tone wheel.

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

Remove the transfer case cover bolts.

14. Use the transfer case pry bosses and separate the transfer case halves.

15. Remove the rear output shaft support bearing.
1 Remove the snap ring.
2 Use the Impact Slide Hammer and Bearing Cup Remover and remove the rear output shaft support bearing.

16. Remove the electromechanical coil nuts.
- Support the coil while removing the nuts.

17. Remove the thrust bearing.

18. Remove the cam coil housing.

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

20. Remove the wave spring.

21. Remove the clutch pack assembly snap ring.

22. 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 it was 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.

23. Remove the front output shaft tone wheel.

24. Remove the drive chain and sprockets.

25. Remove the magnet from its slot in the case, and clean as necessary.

26. Remove the thrust washer.

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

28. CAUTION: Do not disassemble the shift cam assembly.

Remove the shift cam assembly.

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

30. Remove the shift fork shaft.

31. Remove the planetary gear carrier.
1 Depress the planetary gear carrier snap ring.
2 Remove the planetary gear carrier.

32. Remove the planetary gear carrier support bearing.
1 Remove the snap ring.
2 Remove the bearing.

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

34. Remove the front output shaft and flange.
- Remove the snap ring.
- Remove the flange.

35. Use the Seal Remover and the Impact Slide Hammer to remove the front output shaft seal.

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

37. Use the Collet and the Impact Slide Hammer from Blind Hole Puller Set to remove the electric shift motor shaft seal.

38. Use the Impact Slide Hammer and the Bearing Cup Remover to remove the output shaft support bearing.