1 Thru 25

Transfer Case Disassemble

^ Tools Required
- J 8092 Universal Handle
- J 2619-01 Slide Hammer
- J 9276-21 Slide Hammer Adapter
- J 22912-01 Split Plate Bearing Puller
- J 29369-1 Input Gear Remover
- J 29369-2 Bearing Remover
- J 33790 Bearing Remover

Important: If a bearing is found to be defective, it is not recommended that the bearing be replaced separately. The bearing may only be available in a sub assembly.





1. Remove the speed sensor.





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





4. Remove the detent assembly.





5. Remove the first front output shaft retaining ring.
6. Remove the front output shaft rubber washer.
7. Remove the front output shaft seal.
8. Remove the second front output shaft retaining ring.





9. Remove the rear extension housing mounting bolts.
10. Remove the rear extension housing.





11. Remove the rear output shaft retaining ring.





12. Remove the rear output shaft bearing housing mounting bolts.
13. Remove the rear output shaft bearing housing.





14. Remove the first tone wheel retaining ring.
15. Remove the tone wheel.
16. Remove the second tone wheel retaining ring.





17. Remove the transfer case retaining bolts.
18. Remove the rear case half from the front case half.





19. Remove the oil pump pick up assembly.
20. Remove the oil pump assembly.





Important: If the drive chain is to be reused, mark the relationship of the drive chain to the sprockets. This will ensure that the wear pattern on the drive chain and the drive sprockets will be matched during reassembly.
The drive sprocket is part of the synchronizer assembly and can only be removed from the front end.
Also, the drive sprocket is part of the front output shaft and not a separate part.

21. Remove the drive chain and the front output shaft.





22. Remove the mode fork retaining spring assembly.





Important: When performing the following service procedure, remove the mainshaft and the mode fork as an assembly.

23. Remove the mainshaft assembly.





24. Remove the mode fork from the mainshaft.





25. Remove the low range fork assembly.