Disassembly

Transfer Case - Mechanical Shift

Special Tool(s):

Special Tool(s):

Special Tool(s):

Material:

Transfer Case Exploded View - Mechanical Shift:

Disassembly

CAUTION: Discard all seals after removing them.

NOTE: Place the transfer case in the NEUTRAL position for disassembly.

1. Remove the transfer case.

2. WARNING: Wear protective EYEWEAR whenever using compressed air.

Clean the transfer case with solvent and dry with compressed air.

3. WARNING: Make sure the special tool lock pin is secure.

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





4. Remove the mode indicator switch.





5. Using a suitable tool, remove the rear output shaft seal.





6. If not done previously, remove the drain plug and drain the fluid.





7. Review the transfer case symptom chart before and during the disassembly procedure.

Mechanical Shift Transfer Case Symptom Chart

Mechanical Shift Transfer Case Symptom Chart (part 1):

Mechanical Shift Transfer Case Symptom Chart (part 2):

Mechanical Shift Transfer Case Symptom Chart (part 3):

8. Remove the coil return wire from the electrical connector.
1 Remove the wire connector spacer.
2 Remove the coil wire and pin.
^ Use an electrical connector pin extractor tool.





9. Remove the output shaft speed (OSS) sensor.





10. Remove the extension housing.
1 Remove the 6 extension housing bolts.
2 Remove the extension housing.





11. Remove the speed sensor tone wheel.
1 Remove the tone wheel spacer clip.
2 Pull off the speed sensor tone wheel and discard.





12. Remove the rear output shaft snap ring.
^ Lift up on the output shaft while removing the snap ring.





13. NOTE: The bolts are self-tapping, and it is normal to find metal shavings while removing the cover.

Remove the bolts.





14. NOTE: Use pry bosses to separate the cover from the case.

Separate the transfer case covers.





15. Remove the coil.
1 Remove the 3 coil-to-cover nuts.
2 Remove the coil.





16. Using the special tools, remove the rear output shaft bearing.





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





18. Remove the shift collar hub snap ring.





19. Remove the coil housing.





20. Remove the shift fork.
1 Remove the lockup hub.
2 Remove the shift fork and spring.





21. NOTE: Remove the lockup hub assembly as a single unit. If disassembly is required, proceed with the following.

Disassemble the lockup hub assembly.
1 Remove the lockup hub snap ring.
2 Separate the lockup collar.
3 Separate the 2 lockup springs.
4 Separate the lockup hub.
5 Remove the armature.





22. Remove the spacer.





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





24. Remove the magnet from its slot in the case.





25. NOTE: The pump assembly is not repairable.

Remove the oil pump and the output shaft as an assembly.
^ Remove the oil pump from the output shaft.





26. Remove the shift rail.





27. Remove the shift fork and the reduction hub.
1 Remove the shift fork.
2 Remove the reduction hub.





28. Using the special tool, remove the input seal.





29. CAUTION: Do not let the front planet carrier fall while removing the snap ring.

Remove the front planet carrier.
1 Remove the front planet carrier snap ring.
2 Remove the front planet carrier.





30. If necessary, using the special tools, remove the bushing from the front planet.





31. Using a drift and a hammer, remove the needle bearing, if necessary.





32. Remove the ring gear.
1 Remove the ring gear snap ring.
2 Remove the ring gear.





33. Remove the front planet carrier bearing snap ring. Then, using the special tools, remove the front planet carrier bearing.





34. CAUTION: Do not let the front output shaft fall while removing the snap ring.

Remove the front output shaft.
1 Remove the front output shaft snap ring.
2 Remove the front output shaft.





35. Using the special tools, remove the front output shaft bearing.





36. Using the special tools, remove the front yoke to flange seal.





37. NOTE: Access the shift lever set screw through the mode indicator switch hole.

Loosen the shift lever set screw.





38. Remove the shift lever (from outside of case), shift cam detent spring and detent roller.





39. Using the special tools, remove the shift lever seal.





40. Remove the dust shield, if necessary.