Steps 1-30

Transfer Case Disassemble

Important: The following service procedure will cover light duty, heavy duty, and super duty version of this transfer cases.





1. Remove the rear output shaft seal.





2. Remove the rubber plug.





3. Remove the transfer case speed sensor.





4. Remove the gear indicator switch.





5. Remove the vent tube ONLY if the vent tube elbow is damaged.





6. Remove the transfer case retaining bolts.





7. Insert a screwdriver into the slot on the left side of the transfer case.





8. Insert a screwdriver into the slot on the right side of the transfer case.
9. With equal pressure applied on each screwdriver, separate the front half and the rear half.





10. Using a pair of snap ring pliers, release the outside retaining ring for the rear output shaft bearing.





11. Remove the rear case halt from the front case half.





12. Remove the rear output shaft bearing retaining ring.





13. Remove the rear output shaft bearing.





Important: The super duty version of the NVG 261 transfer case does not use a retaining ring for the tone wheel.

14. Remove the tone wheel retaining ring.





15. Remove the tone wheel.





16. Remove the oil pump wear sleeve (only if the sleeve is worn or damaged).





17. Remove the oil pump pick-up tube from the oil pump assembly.
18. Remove the oil pump screen.
19. Disconnect the connector between the oil pump tube to the oil pump screen.





20. Remove the magnet.





21. Remove the oil pump assembly.





22. Remove the seal for the oil pump pick-up tube.





Important: The super duty version of the NVG 261 transfer case does not use a oil pump seal.

23. Remove the seal for the oil pump.





24. Remove the shift rail spring.





25. Remove the driven sprocket retaining ring.





26. Remove the drive sprocket retaining ring.





Important: If the drive chain and sprockets are to be reused, mark the position drive chain to the drive sprockets in order to ensure that any wear patterns will be matched for proper installation.

27. Remove the drive chain and the sprockets.





Important: When removing the synchronizer assembly and mainshaft, remove the shift fork at the same time.

28. Remove the mainshaft assembly.
29. Remove the range fork assembly.





30. Remove the mode fork assembly.