Overhaul

Transfer Case

Special Tool(s):

Special Tool(s):

Material:

Disassembly

1. WARNING: Make sure protective EYEWEAR is in place.

WARNING: Use a petroleum-based solvent to clean the transfer case. Refer to the solvent manufacturer's safety precautions to prevent personal injury or transfer case damage.

CAUTION: Seal all openings before cleaning the transfer case exterior. This will prevent entry of dirt and water, which can cause damage to internal components.

Clean the transfer case exterior with solvent and dry with compressed air.
2. Using special tool 307-003, secure the transfer case to a work bench. Rotate the transfer case so that the output shaft is pointing upward.
3. Drain the fluid from the transfer case, if not done previously.
4. Using a suitable tool, remove and discard the oil seal.





5. Remove the coil wire pin from the electrical connector.
^ Remove the wire connector spacer.
^ Remove the coil wire pin (tan wire).
^ Use an electrical connector pin extractor tool.
6. Remove the bolts and transfer case shift motor.
7. Remove the 3 coil nuts and washers.





8. NOTE: It is normal to find metal shavings after removing the self-tapping transfer case bolts.

Remove the 20 bolts.





9. Separate the transfer case halves.
^ Use the pry bosses to separate the case halves.





10. Using the special tool, remove the rear output shaft support bearing.





11. Using the special tool, remove the front output shaft rear bearing.





12. Remove the snap ring.
^ Inspect the snap ring for wear or damage.
Install a new snap ring as necessary.
13. Remove the caged thrust bearing assembly.
^ Inspect the bearing for wear or damage.
Install a new bearing as necessary.
14. Remove the cam/coil housing.





15. Remove the steel balls and the cam.





16. Remove the wave spring.
17. Remove and discard the snap ring.





18. CAUTION: When removing 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 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.





19. Remove the drive chain and the sprockets as an assembly.
^ Inspect the drive chain for wear or damage. Inspect the sprockets for broken or cracked teeth. Install new components as necessary.





20. Remove the thrust bearing assembly.
1 Remove the thrust washer.
^ The upper thrust washer may be attached to the sprocket.
2 Remove the thrust bearing.
3 Remove the thrust washer.
^ Inspect the washers and bearing for wear or damage. Install new components as necessary.





21. Remove and clean the oil pan magnet.





22. Remove the output shaft sprocket.





23. Remove the oil pump assembly.





24. Remove the output shaft.





25. WARNING: Do not disassemble the shift cam assembly.

Remove the reduction shift fork, the reduction hub and the shift cam as an assembly.
^ Separate and inspect the reduction hub and the reduction shift fork for wear or damage.





26. Remove the shift fork shaft.





27. Remove the front planet.
^ Using a drift and a hammer, remove the front planet needle bearing, if necessary.





28. Remove the ring gear.
1 Remove the snap ring.
^ Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
2 Remove the ring gear.





29. CAUTION: Do not let the front output shaft fall when removing the snap ring.

Remove the snap ring and the front output shaft.
^ Inspect the snap ring for wear or damage. Install a new snap ring as necessary.

30. NOTE: Carefully remove the seal, do not damage the seal bore.

Remove and discard the front output shaft oil seal.





31. NOTE: Carefully remove the seal, do not damage the seal bore.

Remove and discard the front input shaft oil seal.





32. Using a suitable driver, remove the front planet support bearing.





33. Using a suitable driver, remove the front output shaft support bearing.





34. Using a suitable tool, remove and discard the shifter shaft seal.





Assembly
1. Lubricate all internal components with the recommended transfer case lubricant during reassembly.
2. Clean the mating surfaces of the cases.
3. Using a suitable press and the special tools, install the front planet support bearing.





4. Using a suitable press and the special tools, install the front output shaft support bearing.





5. Using the special tool, install a new oil seal.





6. CAUTION: Be careful not to crush the seal.

Using the special tool, install a new shifter shaft seal.





7. Install the case to the transmission holding fixture. Secure the case to the work bench.
8. Using special tool 308-249, install a new oil seal.
9. Install the ring gear.
1 Position the ring gear in the case.
2 Install the snap ring.





10. Install the front output shaft and the snap ring.

11. NOTE: If removed, using a suitable press and the special tool 308-085, install the needle bearing into the front planet. Be careful not to crush the bearing cage.

Install the front planet.





12. Install the shift fork shaft.





13. NOTE: Assemble the reduction hub and the reduction shift fork.

Install the reduction shift fork, the reduction hub and the shift cam as an assembly.





14. Install the output shaft.





15. Install the oil pump assembly.
^ Make sure the oil pump finger is in the slot in the case.





16. Install the oil pan magnet into its slot in the case.





17. Install the output shaft sprocket.





18. Install the 3-piece thrust bearing assembly.
1 Install the thrust washer.
2 Install the thrust bearing.
3 Install the thrust washer.





19. Install the drive chain and the sprockets as an assembly.





20. CAUTION: When installing the clutch assembly, do not separate the clutch pack assembly. 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.

Install the clutch pack assembly.





21. Install a new snap ring.





22. Install the wave spring.
23. Install the cam and the steel balls.





24. Install the cam/coil housing.





25. Install the thrust bearing assembly.
26. Install the snap ring.
27. Using a suitable press and the special tool, install the rear output shaft support bearing.





28. Using a suitable press and the special tool, install the front output shaft rear bearing.





29. CAUTION: Applying too much silicone sealant can plug the fluid filter and cause transfer case failure.

Apply a bead of silicone sealant to the transfer case mating surfaces, then position the 2 transfer case halves together. Tighten the transfer case bolts evenly in a star pattern.
^ Position the coil studs through the case holes, make sure the shift cam shaft is aligned with its case bore, and the lockup shift fork spring is in position.
^ Tighten to 24 Nm (18 lb-ft).





30. Install the 3 coil washers and nuts.
^ Tighten to 10 Nm (89 lb-in).
31. Using the special tool, install the oil seal.





32. Install the transfer case shift motor.
^ Tighten the shift motor bolts to 10 Nm (89 lb-in).
33. Install the coil wire pin in the electrical connector.
^ Remove the wire connector spacer.
^ Install the coil wire pin. Reinstall the wire connector spacer.
34. Remove the transfer case from the special tool.