Disassembly

1. Remove the transfer case.

NOTE: On the manual shift transfer case, place the transfer case in the neutral position for disassembly.





2. On manual shift transfer case, remove the 4WD indicator switch.





3. Secure the transfer case.
^ Use the Bench Mounted Holding Fixture.





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





5. Remove the Vehicle Speed Sensor (VSS).
1 Remove the VSS bolt.
2 Remove the VSS.





6. On electrical shift transfer case, remove the transfer case shift motor.
1 Remove the bolts.
2 Remove the transfer case shift motor.





7. Remove the extension housing.
1 Remove the six extension housing bolts.
2 Remove the extension housing.





8. Remove the speedometer gear spacer.
1 Remove the speedometer gear spacer.
2 Push the speedometer drive gear toward the transfer case.





9. Remove the speedometer drive gear.
1 Remove the steel ball.
2 Remove the speedometer drive gear.





10. Remove the rear output shaft snap ring.
^ Lift up on the output shaft while removing the snap ring.





11. Remove the transfer case bolts.

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





12. Remove the transfer case cover.
^ Use pry bosses to separate the cover from the case.





13. Remove the coil.
1 Remove the three coil to cover nuts.
2 Remove the coil.





14. Remove the front output shaft bearing.
^ Use the Slide Hammer and the Bearing Cup Remover.





15. Remove the rear output shaft bearing.
^ Use the Slide Hammer and the Bearing Cup Remover.

16. Remove the shift collar hub.
^ Remove the shift collar hub snap ring from the rear output shaft.





17. Remove the coil housing.





18. Remove the shift fork.
1 Remove the lockup hub.
2 Remove the shift fork and spring.





19. Disassemble the lockup hub assembly.
1 Remove the lockup hub snap ring.
2 Separate the lockup collar.
3 Separate the two lockup springs.
4 Separate the lockup hub.
5 Remove the armature.

NOTE: Remove the lockup hub assembly as a single unit. If disassembly is required, proceed with the steps as shown.





20. Remove the spacer.





21. Remove drive chain and sprocket assembly.





22. Remove the magnet from its slot in the case.





23. Remove the oil pump and the output shaft as an assembly.
^ Remove the oil pump from the output shaft.

NOTE: The pump assembly is not repairable.





24. Remove the shift fork shaft.





25. Remove the shift fork and the reduction hub.
1 Remove the shift fork.
2 Remove the reduction hub.





26. On electrical shift transfer case, remove the electric shift cam assembly.

WARNING: DO NOT DISASSEMBLE SHIFT CAM ASSEMBLY.





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





28. Remove the front planet carrier.
1 Remove the front planet carrier snap ring.
2 Remove the front planet carrier.

CAUTION: Do not let the front planet carrier fall while removing the snap ring.





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





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

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





31. Remove the front yoke to flange seal.
^ Use the Bearing Cup Remover and the Slide Hammer.





32. If necessary, remove the bushing and needle bearing from the front planet carrier.
^ Use 1.25 - 1.50-inch collet, actuator pin and slide hammer from Blind Hole Puller Set for bushing.
^ Use 1 - 1.25-inch collet, actuator pin and slide hammer from Blind Hole Puller Set for bearing.





33. Remove the front planet carrier bearing snap ring.





34. Remove the front planet carrier bearing.
^ Use the Bearing Cup Replacer and the Driver Handle.





35. Remove the front output shaft bearing.
^ Use the Bearing Cup Remover and the Slide Hammer.





36. Loosen the shift lever set screw.

NOTE: On manual shift transfer case, access the shift lever set screw through the 4WD indicator switch hole.





37. On manual shift transfer case, remove the shift lever (from outside of case), shift cam and spring.





38. On manual shift transfer case, remove the shift lever seal.
^ Use the collet and the slide hammer from the Blind Hole Puller Set.





39. On electrical shift transfer case, remove the electric shift motor seal.
^ Use the collet and the slide hammer from the Blind Hole Puller Set.