Transfer Case - Mechanical Shift

Transfer Case - Mechanical Shift













Transfer Case Exploded View - Mechanical Shift

















Disassembly

NOTE: Discard all seals after removing them.

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

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

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





3. Remove the Mode Indication Switch (MIS).





4. Using a suitable seal puller, remove the rear output shaft seal.





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





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

Remove the 20 transfer case bolts.





7. Using the pry bosses, separate the cover from the case.





8. Remove the 3 transfer case field coil nuts, washers and the transfer case field coil.





9. Using the Bearing Cup Remover with the Slide Hammer, remove the rear output shaft bearing.





10. Using the Bearing Cup Remover with the Slide Hammer, remove the front output shaft bearing.





11. Remove the shift collar hub snap ring.





12. Remove the coil housing.





13. Remove the shift fork.

1. Remove the lockup hub.

2. Remove the shift fork and spring.





14. 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.





15. NOTE: Remove the drive chain and sprockets as an assembly.

Remove the drive chain, sprockets and the thrust washer.





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





17. NOTE: The pump assembly is not repairable.

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





18. Remove the shift rail.





19. Remove the shift fork and the reduction hub.

1. Remove the shift fork.

2. Remove the reduction hub.





20. Remove the front planet carrier.





21. Using the Oil Seal Remover, remove the input seal.





22. Remove the thrust bearing. Using a drift and a hammer, remove the needle bearing, if necessary.





23. Remove the ring gear.

1. Remove the ring gear snap ring.

2. Remove the ring gear.





24. Using the Stator Bearing Remover with the Slide Hammer, remove the front planet carrier bearing.





25. NOTICE: Do not let the front output shaft fall while removing the snap ring or damage to the component may occur.

Remove the front output shaft.

1. Remove the front output shaft snap ring.

2. Remove the front output shaft.





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





27. Using the Bearing Cup Remover with the Slide Hammer, remove the front output shaft seal.





28. NOTE: Access the shift lever set screw through the MIS hole.

Loosen the shift lever set screw.





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





30. Using the Collet with the Slide Hammer, remove the shift lever seal.





Assembly

1. Using the Valve Stem Oil Seal Installer, install the shift lever seal.





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





3. NOTE: Access the shift lever set screw through the MIS hole.

Tighten the shift lever set screw.
- Tighten to 10 Nm (89 lb-in).





4. Using a suitable press and the Bearing Cup Installer with the Handle, install the front output shaft bearing.





5. Using the Input Shaft Oil Seal Installer, install the front output shaft seal.





6. Install the front output shaft.

1. Position the front output shaft.

2. Install the front output shaft snap ring.





7. Using a press and a suitable bearing installer, install the front planet carrier bearing.





8. Position the ring gear into the case. Install the ring gear snap ring.

9. If removed, using a suitable press and the Input Shaft Bearing Installer, install the needle bearing into the front planet carrier.





10. Install the front planet carrier and the thrust bearing.





11. Using the Shaft Oil Seal Protector and the Input Shaft Oil Seal Installer, install the input seal.





12. Install the shift fork and the reduction hub.





13. Install the shift rail.





14. Install the oil pump, output shaft and the thrust washer.





15. Install the magnet into its slot in the case.





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





17. Install the lockup hub. If the lockup hub assembly was disassembled, carry out the following steps.

1. Position the lockup collar.

2. Install the lockup collar springs.

3. Install the lockup hub.

4. Install the armature.

5. Install the lockup hub snap ring.





18. Install the lockup hub and the shift fork and spring.





19. Install the coil housing.





20. Install the snap ring.





21. Using the Mainshaft Bearing Installer, install the rear output shaft bearing.





22. Using the Mainshaft Bearing Installer, install the front output shaft bearing.





23. Install the transfer case field coil, washers and the 3 nuts.
- Tighten to 10 Nm (89 lb-in).





24. NOTICE: If too much silicone sealant is used when sealing the cover to the case, the excess sealant can plug the fluid filter and cause transfer case failure.

Apply a small bead of silicone sealant to the mating surfaces of the case.

25. Position the 2 transfer case halves and tighten the 20 transfer case bolts in the sequence shown.
- Tighten to 24 Nm (18 lb-ft).





26. Using the Input Shaft Oil Seal Installer, install the rear output shaft seal, if removed.





27. Install the MIS.
- Tighten to 41 Nm (30 lb-ft).





28. Remove the transfer case from the Transmission Holding Fixture.