Steps 1-30

Transfer Case Disassemble

^ Tools Required
- J 22912-01 Split Plate Bearing Puller

Important: DO NOT remove the sector shaft or the sector shaft bearing and seal. If the sector shaft bearing is damaged or leaking, a new front case will be needed.
If the tone wheel is damaged, DO NOT replace it. Replace the front output shaft assembly.





1. Remove the motor/encoder mounting bolts.
2. Remove the motor/encoder assembly.
3. Remove the motor/encoder gasket.





4. Remove the vent tube elbow and the seal (if damaged).





5. Remove the rear speed sensors.





6. Remove the front speed sensor.





7. Remove the rubber plug.





8. Pry the inner race back with a flat tipped screw driver, but slipping it between the race and the axial sealing lips.
9. Remove the outer seal by prying it out of the transfer case.





Important: When performing this service operation, use caution as to not damage the transfer case or the sealing surface of the input shaft.

10. Remove the transfer case input shaft seal.





11. Remove the transfer case rear output shaft seal.





12. Remove the transfer case mounting studs (if damaged).





13. Remove the transfer case retaining bolts.





14. Insert a flat-bladed screwdriver into the slot on the left side of the transfer case.





15. Insert a flat-bladed screwdriver into the slot on the right side of the transfer case.
16. With equal pressure, press down on the screwdrivers in order to separate the front case half and the rear case half.





17. Insert a pair of snap ring pliers and release the outer retaining ring for the rear output shaft bearing.





18. Remove the rear case half from the front case half.





19. Remove the oil pump wear clip (only if the wear clip is worn or loose).





20. Remove the first rear output shaft bearing retaining ring.





21. Remove the rear output shaft bearing.





22. Remove the tone wheel retaining ring.





23. Remove the tone wheel.





24. Remove the magnet.





25. Remove the oil pump pickup tube from the screen.
26. Remove the oil screen from the front case half.
27. Remove the oil pump pickup tube from the oil pump inlet hole.





28. Remove the oil pump assembly.





29. Remove the drive sprocket retaining ring.





30. Remove the driven sprocket retaining ring.