Transfer Case - 1-Speed Torque-On-Demand

Transfer Case - 1-Speed Torque-On-Demand

























Disassembly

1. Remove the transfer case. For additional information, refer to Transfer Case Removal.

2. WARNING: Always verify that the lockpin on the bench-mounted holding fixture is correctly secured to help prevent unexpected component rotation. Failure to follow this instruction may result in serious personal injury.

Using the Transmission Holding Fixture, secure the transfer case to the bench.





3. If not previously done, remove the drain plug and drain the fluid.
- When finished draining, install the drain plug and tighten to 20 Nm (177 lb-in).





4. Using the Drive Pinion Flange Holding Fixture to hold the rear output flange, remove the rear output shaft flange nut.





5. Remove the output shaft yoke washer.

6. Using the Output Shaft Flange Remover, remove the rear output shaft flange.





7. Remove and discard the output flange oil seal.

8. Using the Bushing Remover with the Slide Hammer, remove and discard the yoke-to-flange seal.





9. Remove the connector interlock from the electrical connector. Using an electrical connector pin extractor tool, remove the coil wire pin.





10. Remove the 17 transfer case bolts.





11. Remove the 3 clutch coil assembly nuts.





12. NOTICE: Pry only at the transfer case pry bosses. Prying other than at the pry bosses may cause damage to the components.

Separate the transfer case halves at the transfer case pry bosses.





13. Remove the snap ring, then using the Slide Hammer and the Stator Bearing Remover, remove the rear output shaft support bearing.





14. Using the Slide Hammer and the Stator Bearing Remover, remove the front output shaft rear bearing.





15. Remove the thrust bearing.





16. Remove the cam and coil housing assembly.





17. Remove the apply cam and 3 steel balls.

18. Remove the wave spring.





19. Remove the snap ring.





20. NOTICE: When removing or installing 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 it was 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.

21. Remove the drive chain and the 2 sprockets as an assembly.





22. Remove and clean the oil pan magnet.





23. Remove the thrust washer.





24. Remove the pump assembly and the rear output shaft as an assembly. Do not disassemble the pump assembly.





25. Using the Oil Seal Remover, remove the oil seal.





26. While holding the front output shaft and flange, remove the snap ring.





27. Remove the front output shaft and flange.





28. Using the Bearing Cup Remover with the Slide Hammer, remove the oil seal.





29. Using the Stator Bearing Remover with the Slide Hammer, remove the front output shaft support bearing.





Assembly

1. Using the Differential Bearing Cup Installer with the Adapter, press the front output shaft support bearing into the case.





2. Using the Input Shaft Oil Seal Installer, install the oil seal.





3. Using the Input Shaft Oil Seal Installer, install the oil seal.





4. Install the front output shaft and flange and snap ring.





5. Install the pump assembly and the rear output shaft as an assembly.





6. Install the thrust washer.





7. Install the oil pan magnet.





8. Install the drive chain and the 2 sprockets as an assembly.

9. NOTICE: When removing or installing 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 it was 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.

Install the clutch pack assembly.

10. Install a new snap ring.





11. Install the wave spring.





12. Install the apply cam and 3 steel balls.

13. Install the cam and coil housing assembly.





14. Install the thrust bearing.





15. Using the Wheel Hub Bearing Cup Installer with the Adapter, install the front output shaft rear bearing into the case.





16. Using the Wheel Hub Bearing Cup Installer with the Adapter, install the rear output shaft rear bearing into the case.





17. Position and support the clutch coil assembly, then install the 3 nuts.
- Tighten to 10 Nm (89 lb-in).





18. NOTICE: Applying excess gasket sealant can damage the internal components.

Apply a 3 mm (0.11 in) bead of gasket sealant on the rear case mating surface.





19. Assemble the front and rear case halves.

20. Install the 17 transfer case bolts.
- Tighten the bolts evenly in a cross pattern to 25 Nm (18 lb-ft).





21. Using the Input Shaft Oil Seal Installer, install the yoke-to-flange oil seal.





22. Install a new output flange oil seal.

23. NOTE: Align the index marks made during disassembly.

Install the output flange.

24. Install the output shaft yoke washer.

25. Using the Drive Pinion Flange Holding Fixture to hold the output flange, install the nut.
- Tighten to 355 Nm (262 lb-ft).





26. Seat the coil wire pin into the electrical connector and install the connector interlock.





27. Install the transfer case in the vehicle. For additional information, refer to Transfer Case Installation.

28. Fill the transfer case. For additional information, refer to Transfer Case Draining and Filling Procedures.