Disassembly

Special Tools:

Special Tools:

Special Tools:

Special Tools:

Disassembly

1. CAUTION: During disassembly, all nuts, bolts and retaining rings are to be discarded and replaced with new components during assembly.

Remove the transfer case from the vehicle and mount the transfer case on a holding fixture.





2. On the electric shift transfer case, remove the gearmotor encoder assembly.





3. On the manual shift transfer case, remove the 3 position switch.

4. CAUTION: Do not use air tools to remove the plugs.





Remove the drain and fill plugs.





5. While using the Companion Flange Holding Tool to prevent the flange from turning, remove and discard the nut.





6. Using the Flange Remover, remove the flange.





7. While using the Companion Flange Holding Tool, to prevent the flange from turning, remove and discard the nut.





8. Using the Flange Remover, remove the flange.





9. Remove the slinger from the front flange and the rear flange if replacement is necessary.





10. Using the Converter Oil Seal Remover, remove the rear output seal.





11. Remove and discard the rear retainer retaining bolts.





12. Using the Transfer Case Housing Spreader, remove the rear retainer.





13. Using the Front Pump Bushing Remover, the Handle and a suitable press, remove the needle bearing.





14. Disconnect the oil tube and remove the oil pump assembly.





15. Remove the retaining ring.
1. Install the Rear Output Shaft Snap Ring Sleeve.
2. Lift up on the shaft, and remove and discard the retaining ring.





16. Remove and discard the 25 case bolts.





17. Using the Transfer Case Housing Spreader, separate the case halves.





18. Remove the oil tube.





19. Remove the ball bearing retaining ring.





20. Using the 205-138 Pinion Bearing Cup Replacer, the Handle and a suitable press, remove the ball bearing.





21. Using the Blind Hole Puller Set and the Slide Hammer, remove the needle bearing.





22. Remove the chip collector magnet.





23. Remove the driven sprocket retaining ring.





24. Remove the drive sprocket retaining ring.





25. Remove the mode spring.





26. Remove the sprockets and chain as an assembly.





27. Remove the mainshaft and mode fork assembly as an assembly.





28. Slide the mode fork and synchronizer sleeve off of the mainshaft, and separate the components.
29. Place the mainshaft in a soft jawed vise with the threaded end up.





30. Remove the clutch gear.





31. Remove the retaining ring and the synchronizer hub.





32. On the electric shift transfer case mainshaft, remove the outer ring.





33. On the electric shift transfer case mainshaft, remove the middle ring.





34. On the electric shift transfer case mainshaft, remove the inner ring.





35. Remove the drive sprocket hub.
36. Inspect all of the components for wear and damage.





37. Inspect the mode fork pads for wear.

38. Note: Rotate the sector assembly to the 4-wheel high position for easy removal.





Remove the range fork assembly and the range shift sleeve.





39. Inspect the range fork pads.





40. Using the Converter Oil Seal Remover, remove the input seal.





41. Remove the retaining ring.
1. Install the Input Shaft Snap Ring Sleeve.
2. Remove and discard the retaining ring.





42. Remove the planetary assembly.





43. Remove the input bearing retaining ring.





44. Using the 205-140 Pinion Bearing Cup Replacer and a suitable press, remove the front input bearing.





45. Using the Converter Oil Seal Remover, remove the front output seal.





46. Remove the retaining ring.
1. Install the Front Output Shaft Snap Ring Sleeve.
2. Remove and discard the retaining ring.





47. Remove the sleeve and the front output shaft.





48. Remove the front output ball bearing retaining ring.





49. Using the Rear Axle Seal Replacer, the Handle and a suitable press, remove the front output ball bearing.





50. Remove the lock plate retaining ring.





51. Lift out the input gear.





52. Remove the lock plate.





53. Remove the front input gear thrust washer.





54. Remove the rear input gear thrust washer.





55. Inspect the gear teeth and thrust washers for wear and damage. Replace the planetary gear assembly, if necessary.





56. Remove the poppet assembly.





57. Disassemble the poppet screw, spring and poppet.





58. On the manual shift transfer case, remove the locknut, washer, lever, spacer and the sector assembly.





59. On the electric shift transfer case, remove the plastic retainer and O-ring and remove the sector assembly.





60. Using the Sector Shaft Nut Socket, remove the sector shaft support (motor adapter for electric shift transfer case).





61. Remove and discard the support O-ring seal.