Steps 31-65

Transfer Case Disassemble (Continued)





Important: If the drive chain and sprockets are to be reused, mark the relationship of the drive chain to the drive sprockets in order to mark the wear patterns.

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





32. Remove the mainshaft assembly.





33. Remove the thrust bearing support assembly retaining ring.





34. Remove the thrust bearing support assembly.





35. Remove the thrust bearing from the inner bearing support plate.
36. Remove the inner bearing support plate from the outer bearing support plate.
37. Using a press, remove the inner bearing support from the thrust bearing.





Important: When performing this service procedure, do not wash these disc, replace them.

38. Remove the clutch pack assembly from the outer drum assembly.





39. Remove the inner clutch drum retaining ring.





40. Remove the clutch spring washer (non preload shown-preload has will have a large wavy washer).





41. Remove the inner drum.





42. Remove the outer drum.





43. Remove the oil restricter from the mainshaft (only if the mainshaft is to be replaced).





44. Using a brass drift and a hammer, remove the clutch outer drum bearings.





45. Remove the clutch lever inserts (left side shown).





46. Remove the clutch lever from the sector shaft assembly.





47. Remove the shift rail.





48. Remove the range fork and the range shift sleeve as an assembly.





49. Remove the range shift sleeve from the range fork.





50. Remove the input shaft retaining ring.





51. Remove the planetary gear assembly.





52. Remove the front output shaft retaining ring.





53. Remove the front output shaft assembly.





Important: When performing the following service procedure, reverse the way J- 22912-01 is normally installed. This will allow greater tool contact area when removing the front output shaft bearing.

54. Using the J 22912-01 and a press, remove the front output shaft bearing.





55. Remove the cap from the front output shaft (only if leaking).





56. Remove the thrust plate retaining ring.





57. Remove the thrust plate.





58. Remove the second thrust washer.





59. Remove the input gear from the planetary gear.





Important: Only perform the following service procedure if the bearing or plug is damaged or leaking.

60. Remove the pilot bearing from the input gear.





61. Remove the thrust washer.





62. Remove the input shaft bearing retaining ring.





63. Remove the input gear bearing.





64. Remove the poppet assembly.





65. Remove the drain and fill plugs.