Steps 1 - 30

Part 1 of 2





Part 2 of 2

Special Tool(s)

Disassembly

CAUTION: Discard all nuts, bolts, and retaining rings after removing them from the transfer case. Install all new fasteners during transfer case assembly.





All transfer cases
1. Attach the transfer case to the special tool.





Electric shift transfer case
2. Remove the gear motor encoder assembly.





Manual shift transfer case
3. Remove the 3 position switch.





All transfer cases

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

Remove the drain and fill plugs.





5. Remove and discard the nut.
- Use the special tool to prevent the flange from turning.





6. Using a suitable 2 or 3 jaw puller, remove the flange.





7. Remove and discard the nut.
- Use the special tool to prevent the flange from turning.





8. Using a suitable 2 or 3 jaw puller, remove the flange.





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





10. Using the special tools, remove the rear output seal.





11. Remove and discard the eight bolts retaining the rear retainer to the rear case.





12. Remove the rear retainer.
- Use the special tool to separate the rear retainer from the rear case.





13. Using the special tools and a suitable press, remove the needle bearing.





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





15. Remove and discard the retaining ring.
1 Install the special tool.
2 Lift up on the shaft, and remove and discard the retaining ring.
- Remove the special tool.





16. Remove and discard the 25 bolts retaining the rear case to the front case.





17. Remove the rear case.
- Use the special tool to separate the case halves.





18. Remove the oil tube.





19. Remove the ball bearing retaining ring.





20. Using the special tools and a suitable press, remove the ball bearing.





21. Using the special tool, 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 the mode fork assembly as an assembly.





28. Slide the mode fork and synchronizer sleeve off the mainshaft, and separate the components.
- Mode sleeve for mechanical shift or synchronizer sleeve for electric shift.





29. Place the mainshaft in a soft jawed vise with the threaded end upward.





30. Remove the clutch gear.