Disassembly

1. Remove front output flange nut, steel flat washer and rubber sealing washer from front output shaft.

2. Remove front output flange from front output shaft.

3. Remove speed sensor retaining bolt and speed sensor from extension housing.






4. Remove front cover retaining bolts from rear case half.

5. Remove front cover, then the front output shaft spacer from front output shaft.

6. Remove front output shaft, drive chain and driven sprocket from rear case half.

7. Remove magnet from rear case half.

8. Remove sun gear shaft, sun gear shaft bearing, drive sprocket spacer, drive sprocket, viscous clutch and sun gear shaft thrust washer as an assembly from planetary carrier assembly.

9. Remove planetary carrier assembly and thrust washer from output shaft assembly.

10. Remove extension housing retaining bolts.

11. Remove breather assembly from extension housing.

12. Remove extension housing from rear case half.

13. Turn rear case half over and support output shaft assembly from inside of rear case half.






14. Remove output shaft bearing snap ring.

15. Remove gear ring snap ring from gear ring.

16. Remove output shaft assembly from gear ring.

17. Remove front output shaft and input shaft oil seal from front cover.

18. Remove output shaft bearing snap ring.

19. Remove bearing from front cover, then the output shaft oil seal from extension housing.

20. Using tool No. J-22912-01, or equivalent, press sun gear shaft bearing from sun gear shaft.

21. Using tool No. J-23907, or equivalent, remove drive sprocket spacer, drive sprocket and viscous clutch from sun gear shaft assembly.

Fig. 50 Removing Input Pilot Shaft Bearing. Borg-Warner 4472 Transfer Case:

22. Using tool No. J-2907, or equivalent, remove input shaft pilot bearing from output shaft assembly.






23. Using slide hammer tool No. J-2619-01 and output shaft bearing remover tool No. J-29369, or equivalent, remove output shaft rear bearing from rear case.