Disassembly

Special Tools:

Special Tools:

Special Tools:

Disassembly

1. CAUTION: Discard all seals after removing them.

Remove the transfer case from the vehicle.





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

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





3. If not done previously, remove the drain plug and drain the fluid.
- Install the drain plug when finished draining.





4. Index-mark the rear output flange and the upper output shaft.





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





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





7. Remove the 17 bolts.





8. Using a pry bar, separate the front and rear case halves.





9. CAUTION: Do not remove the needle bearing from the upper output shaft.

Remove the upper output shaft and the ring gear.
1. Expand the snap ring.
2. Remove the upper output shaft and the ring gear.
3. Remove the snap ring.





10. Remove the snap ring and the bearing.





11. Remove the snap ring, and separate the ring gear from the upper output shaft.





12. Using a suitable tool, remove the yoke to flange seal.





13. Using a suitable tool, remove the bearing.





14. Remove the output shaft thrust washer.





15. Remove the front planetary gear assembly.





16. Remove the thrust washer.





17. CAUTION: Do not remove the bushing or pinion bearing from the viscous coupling. If component wear/damage is evident, discard the viscous coupling.

Remove the viscous coupling with the upper drive sprocket, the drive chain, and the lower drive sprocket.





18. Using a suitable press and the special tool, press the bearing off of the overdrive sun gear.





19. Separate the upper drive sprocket and the overdrive sun gear from the viscous coupling.





20. Remove the input shaft assembly.





21. Remove the damper snubbers.





22. CAUTION: Support the front output shaft while removing the snap ring.

Remove the front output shaft.
1. Remove the snap ring.
2. Remove the front output shaft.
- Use a soft-face hammer, if necessary.





23. Using the special tools, remove the bearing.





24. Using the special tools, remove the bushing, if necessary.





25. Using a suitable tool, remove the yoke to flange seal.





26. Using a suitable tool, remove the yoke to flange seal.