Disassembly

Special Tools:

Transfer Case Exploded View - Manual Shift

Transfer Case Exploded View - Electric Shift

Disassembly

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

1. Remove the transfer case.

2. Remove the 4WD indicator switch, if equips

3. Using the special tool, secure the transfer case.

4. Using a suitable tool, remove the oil seal.

5. Remove the coil wire from the electric shift motor electrical connector, if equipped.
1 Remove the wire connector spacer.
2 Remove the coil wire and pin. Use an electrical connector pin extractor tool.

6. Remove the Output Shaft Speed Sensor (OSS), if equipped.

7. Remove the transfer case shift motor, if equipped.
1 Remove the bolts.
2 Remove the transfer case shift motor.

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

9. Remove the speed sensor tone wheel, if equipped.
1 Remove the tone wheel spacer clip.
2 Push off the speed sensor tone wheel and discard.

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

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

Remove the bolts.

12. Note: Use pry bosses to separate the cover from the case.

Remove the transfer case cover.

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

14. Using the special tools, remove the rear output shaft bearing.

15. Using the special tools, remove the front output shaft bearing.

16. Remove the shift collar hub snap ring and the bearing.

17. Remove the coil housing.

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

19. Note: Remove the lockup hub assembly as a single unit. If disassembly is required, proceed with the following.

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.

20. Remove the spacer.

21. Remove the drive chain and sprocket assembly.

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

23. Note: The pump assembly is not repairable.

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

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. WARNING: Do not disassemble shift cam assembly.

Remove the electric shift cam assembly, if equipped.

27. Using the special tool, remove the input-seal.

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

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

29. If necessary, using the special tools, remove the bushing from the front planet.

30. Using a drift and a hammer, remove the needle bearing, if necessary.

31. If front planet support bearing removal is necessary, remove the snap ring.

32. Using a suitable press and the special tool, remove the front planet support bearing.

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

34. Remove the front planet carrier bearing snap ring.

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

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

36. Using the special tools, remove the front output shaft bearing.

37. Remove the shift lever (from outside of case), shift cam and spring, if equipped.

38. Using the special tools, remove the front yoke to flange seal.

39. Note: Access the shift lever set screw through the 4WD indicator switch hole, if equipped.

Loosen the shift lever set screw.

40. Using the special tools, remove the shift lever seal, if equipped.

41. Use a suitable pry tool to remove the electrical shift motor seal, if equipped.

42. Remove the dust shield, if necessary.