Disassembly

Special Tools:

Special Tools:

Special Tools:

Special Tools:

Disassembly

1. Remove the transfer case.





2. WARNING: Make sure the Holding Fixture lock pin is secure.

Using the special tool, secure the transfer case to a bench.





3. Index-mark the rear output flange and the rear output shaft.





4. Use the special tool to hold the rear output flange while removing the nut.





5. Remove the rear output flange.
1. Remove the output shaft yoke washer.
2. Remove the oil seal.
3. Remove the rear output flange.





6. Using the special tools, remove the oil seal.





7. Remove the coil wire pin from the electrical connector.
1. Remove the connector interlock.
2. Remove the coil wire pin.
- Use electrical connector pin extractor tool.





8. CAUTION: Note each sensor wire pin location for correct installation.

Remove the front and rear output shaft speed sensor wire pins from the electrical connector.
- Use an electrical connector pin extractor tool.





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





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





11. Remove the bolt and the rear output shaft speed sensor.





12. Remove the spacer.

13. Note: Inspect the tone wheel teeth for damage.

If necessary, remove and discard the tone wheel.





14. Remove the 17 bolts.





15. Separate the transfer case halves at the transfer case pry bosses.





16. CAUTION: Support the clutch coil assembly while removing the nuts.

Remove the nuts and the clutch coil assembly.





17. Using the special tools, remove the front output shaft rear bearing, and remove the rear output shaft support bearing.





18. Remove the snap ring.





19. Remove the thrust bearing.





20. Remove the cam and coil housing assembly.





21. Remove the apply cam and balls.
1. Remove the steel balls.
2. Remove the apply cam.





22. Remove the wave spring.





23. Remove the snap ring.





24. 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 it in place. If the thrust washer is not in place, a transfer case clearance problem can occur.

Remove the clutch pack assembly.





25. Remove the tone wheel.





26. Remove the drive chain and the sprockets as an assembly.





27. Remove and clean the oil pan magnet.





28. Remove the thrust washer.





29. CAUTION: Do not disassemble the pump assembly.

Remove the pump assembly and the rear output shaft as an assembly.





30. CAUTION: Do not disassemble the electric shift cam assembly.

Remove the electric shift cam assembly.





31. Remove the reduction shift fork and the high-low collar as an assembly.





32. Remove the shift rail.





33. Using the special tool, remove the oil seal.





34. Remove the front planetary gear set assembly.
1. Expand the snap ring.
2. Remove the front planetary gear set assembly.





35. Remove the ring gear, if necessary.
1. Remove the snap ring.
2. Remove the ring gear.





36. If necessary, using a drift and hammer, remove the output shaft bushing and bearing.





37. If planetary gear carrier support bearing removal is necessary, remove the snap ring.





38. Using a suitable press and the special tool, remove the planetary gear carrier support bearing.





39. Remove the snap ring and the front output shaft and flange.





40. Using the special tools, remove the oil seal.





41. Using the special tools, remove the front output shaft support bearing.





42. Using a suitable tool, remove the shifter shaft seal.