Internal Components

New Venture Gear 243 Transfer Case Components:

New Venture Gear 243 Transfer Case - Legend:

- Tools Required:
- J 2619-01 Slide Hammer
- J 8092 Driver Handle
- J 22912-1 Bearing Remover
- J 29369-l Output Shaft Bearing Remover
- J 29369-2 Output Shaft Bearing Remover
- J 9276-21 Slide Hammer Adapter
- J 33832 Bearing installer/Remover

REMOVE OR DISCONNECT

Important
- The annulus gear found in this transfer case is not serviceable or removable and should only be replaced as a unit with the front case half. If the annulus gear is removed, damage to the case will result.




1. Oil pump from the pickup tube and the rear case half.




2. Oil pump pickup tube, O-ring, and pump pickup filter from the rear case half.




3. Mode shift fork spring from the shift rail.
4. Snap ring from the front output shaft.




5. Mainshaft, drive chain, and driven sprocket from the front case half as an assembly.
- Mode shift fork and shift rail will be removed with the mainshaft.




6. Synchronizer to the mainshaft snap ring.




7. Synchronizer assembly from the mainshaft.
8. Drive sprocket from the mainshaft.




9. Range shift fork and range shift hub from planetary carrier.
- It is necessary to remove the selector with shaft to obtain clearance when removing the range fork.




10. Shift lever nut, washer, shift lever, selector and shaft assembly plastic washer, and O-ring seal from the front case half.




11. Three bolts securing shift selector motor to the front case.




12. Input gear snap ring.




13. Input bearing snap ring.




14. Planetary carrier and input gear from the annulus gear using a soft faced hammer.




15. Input gear to planetary carrier assembly snap ring.
16. Input gear from the planetary carrier.
17. Input bearing from the front case half using J 36370 and J 8092.




18. Mainshaft pilot bearing from the input gear using J 29369-1, J 9276-21, and J 2619-01.
19. Front output bearing snap ring.
20. Front output shaft seal from front case half.
21. Front output bearing from front case half using J 33832 and J 8092.
22. Seal from the mainshaft extension housing.
23. Seal from input bearing retainer.




24. Front output rear bearing from rear case half.
25. Mainshaft bearing from the rear retainer housing.




26. Magnet from the front case half.

DISASSEMBLE




- Scribe the location of the synchronizer sleeve and hub to aid in assembly.

1. Main drive synchronizer stop ring from the synchronizer sleeve.
2. Spring retainers from the synchronizer hub.
3. Synchronizer hub from the synchronizer sleeve.
- Be careful not to damage the synchronizer struts when removing the sleeve from the hub.
- The oil pump is not serviceable and should be replaced as a unit only.