1. Transfer Case Disassemble

^ Tools Required
- J 8092 Driver Handle
- J 2619-01 Slide Hammer
- J 9276-21 Slide Hammer to Bearing Remover Adapter
- J 29369-1 Input Gear Bearing Remover
- J 29369-2 Front Output Shaft Rear Bearing Remover
- J 33790 Front Output Shaft Front Bearing Remover





1. Remove the speed sensor.





2. Remove the three bolts securing the motor/encoder to the transfer case.





3. Remove the detent plunger, plunger spring, O-ring, and plunger plug.





4. Remove the retainer ring from the output shaft.
5. Remove the plastic washer from the output shaft.
6. Remove the retaining ring from the output shaft groove.
7. Remove the front output shaft seal from the front case and the front output shaft.





8. Remove the bolts securing the rear extension housing to the output bearing cover.





9. Remove the bearing retaining ring from the groove on the rear output shaft.





10. Remove the five bolts securing the rear output bearing cover to the case.





11. Remove the speedometer tone wheel retaining ring from the output shaft.
12. Remove the speedometer tone wheel from the rear output shaft.
13. Remove the speedometer tone wheel retaining ring from the rear output shaft.





14. Remove the bolts securing the rear case to the front case.





15. Remove the oil pump, O-ring, rubber tube, oil pickup screen, and the oil pump tube from the rear case.





16. Remove the front output shaft and drive chain from the front case and the main shaft.





17. Remove the main shaft and mode fork from the front case and sleeve assembly.





18. Remove the mode fork retaining spring and the retaining spring cover from the mode fork shaft.





19. Remove the mode fork from the mainshaft.





20. Remove the low range fork, sleeve, and hub assembly from the planetary assembly and case.





21. Remove the range shift hub from the low range fork.





22. Remove the retaining ring and plastic sleeve from the sector shaft.





23. Remove the sector shaft from the front case.





24. Remove the O-ring from the sector shaft.





25. Remove the four bolts securing the input shaft bearing retainer to the front case.





26. Remove the snap ring from the input shaft.





27. Remove the planetary assembly from the front case.





28. Remove the retaining ring, synchronizer stop ring, synchronizer/sleeve assembly and the drive sprocket.





29. Remove the clutch sleeve from the synchronizer hub.





30. Remove the retaining ring and three struts from the synchronizer hub.





31. Turn the synchronizer over and remove the retaining ring securing the three struts to the synchronizer hub.





32. Remove the snap ring from the planetary carrier.
33. Remove the steel spacer from the input gear.
34. Remove the fiber washer from the input gear.
35. Remove the input gear from the planetary carrier.
36. Remove the fiber washer from the planetary carrier.





37. Remove the input seal from the input bearing retainer.





38. Remove the output shaft extension housing oil seal.





39. Using J 29369-1, J 9276-21 and J 2619-01, remove the input gear bearing from the input gear.





40. Remove the retaining ring securing the front output shaft front bearing.





41. Using J 3790 and J 8092 remove the front output shaft front bearing from the front case.





42. Using J 29369-2 and J 8092, remove the front output shaft rear roller bearing from the rear case.





43. Using J 33790 and J 8092, remove the output shaft rear bearing from the output shaft rear retainer housing.





44. Remove the bearing retaining ring from the front case.
45. Using J 33790 and J 8092, remove the front input shaft bearing from the front case.