Transfer Case Disassemble

DISASSEMBLY





1. Remove three bolts securing the motor/encoder gasket and motor/encoder to the transfer case.
2. Remove the drain plug.
3. Remove the fill plug.





4. Remove the O-ring and transfer case vent tube from the transfer case.
Vent tube removal is only necessary if the vent tube is damaged.





5. Remove the two rear speed sensors from the rear case.





6. Remove the rear output bearing retaining ring through the retaining ring access hole and from the mainshaft.
7. Remove the rubber plug from the rear case half.





8. Remove the front speed sensor from the front case half.





9. Remove the six input shaft studs from the front case half.





10. Remove the two studs securing the transfer case shield mounting bracket to the transfer case.





11. Remove the case half bolts, studs, and washers from the front and rear case halves.





12. Remove the two case half alignment dowels from the front case half.





13. Remove the rear case half from the front case half.
During the disassembly of the front and rear case halves, the rear output bearing retaining ring must be spread open to allow for the case halves to separate.
Use a rubber mallet to separate the case halves while spreading the rear output bearing retaining ring.





14. Remove the oil pump retainer tab from the rear case half.





15. Remove the tone wheel from the main shaft.
16. Remove the rear output bearing from the main shaft.
17. Remove the rear output bearing retaining ring from the mainshaft.





18. Remove the magnet from the front case half.





19. Remove the oil pump pickup tube from the oil pump inlet hole and O-ring.
20. Remove the oil screen from the front case half.
21. Remove the screen from the nylon tube.





22. Remove the oil pump from the mainshaft.





23. Remove the oil pump o-ring from the oil pump inlet hole.





24. Remove the gerotor pump retaining ring from the mainshaft.





25. Remove the drive and driven sprocket retaining rings from the mainshaft and front output shaft.





26. Remove the chain with the drive and driven sprockets from the mainshaft and front output shaft.





27. Remove the drive sprocket and driven sprocket from the chain.





28. Remove the front output shaft oil seal.





29. Remove the front output shaft retaining ring from the front output shaft and the front case half.
Do not scratch/damage the oil seal surface of the front output shaft with the front output shaft retaining ring.





30. Remove the front output shaft from the front case half.





31. Remove the mainshaft from the front case half.





32. Remove the clutch retaining ring from the mainshaft.





33. Remove the thrust bearing, inner and outer bearing support plates from the main shaft and the inner clutch drum.





34. Using a press, remove the inner bearing support from the thrust bearing.





35. Remove all of the inner clutch plates and outer separator plates.





36. Remove the clutch drum flange.





37. Remove the inner clutch drum retaining ring.





38. Remove the clutch return spring from the mainshaft and the clutch inner drum.





39. Remove the clutch inner drum from the mainshaft and clutch drum.





40. Remove the clutch drum from the mainshaft.





41. Using a press, remove the second clutch outer drum bearing from the mainshaft.





42. Using a press, remove one of the clutch outer drum bearings from the mainshaft.





43. Remove the clutch lever (2) and two clutch lever inserts (1) from the front case half.





44. Remove the front input gear oil seal from the front case half.





45. Remove the front input gear case bearing retaining ring from the front input gear.
- Use snap-ring pliers to remove the retaining ring from the front input gear.
- During removal of the retaining ring, do not scratch/damage the seal surface area of the front input shaft with the retaining ring.





46. Remove the front input gear from the front input gear case bearing.





47. Using a press, remove the front input gear bearing inside the front input gear.





48. Remove the oil fill and drain plugs into the rear case half.





49. Remove the front output shaft rear bearing from the rear case half.





50. Remove the rear output shaft seal from the rear case half.





51. Using a press, remove the rear retainer bushing from the rear case half.





52. Remove the poppet plunger, poppet spring, poppet bolt o-ring, and poppet bolt from the front case half.





53. Remove the sector shaft (2) and the sector retaining ring (1) from the front case half.





54. Remove the sector from the front case half.





55. Remove the sector bearing from the rear case half.





56. Remove the front output shaft bearing retaining ring from the front case half.





57. Using a press, remove the front output shaft bearing from the front case half.





58. Remove the input gear bearing retaining ring into the inside of the front case half.





59. Using a press, remove the input gear bearing from the front case half.