All Wheel Drive

Special Tools:

Special Tools:

1. CAUTION: Seals are damaged upon removal. New seats are required after removal.

Remove the transfer case and place on a workbench.





2. Remove the drain plug and drain the fluid.





3. Mark the rear transfer case flange and the rear output shaft for correct reassembly.





4. Install the Companion Flange Holding Tool to the case yoke.





5. Remove the case yoke.
1 Remove the rear shaft nut.
2 Remove the output shaft yoke washer.
3 Remove the oil seal.
4 Remove the case yoke.





6. Place the transfer case in the Bench Mounted Holding Fixture, and remove the 17 bolts from the front case half and the rear case half.





7. Insert a pry bar and separate the front and rear case halves.

8. CAUTION: Do not remove the bearing from the rear output shaft.





Remove the rear output shaft and ring gear from the rear case half.
1 Place the rear half of the case in the Bench Mounted Holding Fixture.
2 Open the retaining ring.
3 Remove the rear output shaft and rear gear.





9. Remove the output shaft bearing and the speedometer tone wheel.
1 Remove the output shaft bearing.
2 Remove the speedometer tone wheel.





10. Remove the rear yoke to flange seal and the bearing.
1 Pry out the rear output shaft seal.
2 Pull out the rear output shaft bearing.





11. Remove the ring gear from the rear output shaft.
1 Remove the snap ring.
2 Remove the ring gear from the rear output shaft.





12. Place the front case half in the Bench Mounted Holding Fixture, and remove the output shaft thrust washer.





13. Remove the planetary assembly.





14. Remove the output shaft thrust washer.

15. NOTE: Do not remove the viscous clutch bushing or pinion bearing. Replace as part of the viscous clutch assembly.





Remove the viscous clutch with the driven sprocket and the drive chain.





16. Press the bearing off the sun gear shaft with Bearing Pulling Attachment.

17. NOTE: Do not remove the front case half input shaft bushing. Replace as part of the front case half.





Remove the input shaft.





18. Remove the bolts and the two chain snubbers.





19. Remove the front output shaft.
1 Remove the front output shaft retaining ring.
2 Remove the front output shaft with a soft-face hammer.





20. Remove the front output shaft bearing with the Bearing Remover and Impact Slide Hammer.





21. Turn the transfer case front half over in the Bench Mounted Holding Fixture, and pry out the input shaft seat.





22. Pry out the front yoke to flange seal.