Part 2

Transfer Case - Electronic Shift

Disassembly (Steps 30-59)

30. Remove the retaining ring and the synchronizer hub.





31. Remove the outer ring.





32. Remove the middle ring.





33. Remove the inner ring.





34. Remove the drive sprocket hub.





35. Inspect all of the components for wear and damage.
36. Inspect the mode fork pads for wear.





37. NOTE: Manual shift range fork shown, electric shift range fork similar.

NOTE: Rotate the sector assembly to the 4-wheel high position for easy removal.

Remove the range fork assembly and the range shift sleeve.





38. NOTE: Manual shift range fork shown, electric shift range fork similar.

Inspect the range fork pads for wear. If the pads are worn, discard the range fork, the pads, the mainshaft and the sleeve.





39. Using the special tools, remove the input seal.





40. Remove and discard the retaining ring.
1 Install the special tool.
2 Remove and discard the retaining ring.
^ Remove the special tool.





41. Remove the planetary assembly.





42. Remove the input bearing retaining ring.





43. Using the special tool and a suitable press, remove the front input bearing.





44. Using the special tools, remove the front output seal.





45. Remove and discard the retaining ring.
1 Install the special tool.
2 Remove and discard the retaining ring.





46. Remove the special tool and the front output shaft.





47. Remove the front output ball bearing retaining ring.





48. Using the special tools and a suitable press, remove the front output ball bearing.





49. Remove the lock plate retaining ring.





50. Lift out the input gear.
^ Inspect the input gear for wear or damage. Install a new gear if necessary.





51. Remove the lock plate.





52. Remove the front input gear thrust washer.





53. Remove the rear input gear thrust washer.





54. Inspect the gear teeth and thrust washers for wear and damage. Install a new planetary gear assembly, if necessary.





55. Remove the poppet assembly.





56. NOTE: If installing a new poppet spring, it must be like in color to the original poppet spring.

Disassemble the poppet screw, the spring and the poppet.





57. Remove the plastic retainer and the O-ring, and remove the sector assembly.





58. Using the special tool, remove the motor adapter.





59. Remove and discard the support O-ring seal.