Steps 1 - 38

Transfer Case Disassemble

^ Tools Required
- J 22912-01 Split Plate Bearing Puller
- J 23907 Slide Hammer with Bearing Adapter
- J 26941 Bushing and Bearing Remover - 3-4 inch
- J 45380 Transfer Case Rear Bushing Remover and Installer





1. Remove the fiji plug (1) and the drain plug (2) and drain the transfer case fluid.





2. Remove the connector, for the actuator encoder motor wiring harness, from the bracket.

3. Remove the actuator encoder motor mounting bolts.

4. Remove the actuator encoder motor assembly.

5. Remove the actuator insulator gasket.





6. Remove the encoder motor mounting bolts.
7. Remove the encoder motor assembly.
8. Remove the actuator insulator gasket.





9. Remove the vent and the seal, if damaged.





10. Remove the rear Vehicle Speed Sensors (VSS).





11. Remove the front VSS.





12. Remove the access hole plug.





Notice: Refer to Transfer Case Seal Removal Notice in Service Precautions.

13. Remove the input shaft seal by prying it out of the front case.





14. Remove the rear output shaft seal.





15. Inspect the rear output shaft bushing for scoring or wear.
16. Remove the rear output shaft bushing using the J 45380.
^ Install the finger section of the J45380 in front of the bushing.
^ Install the tube and forcing screw assembly to the finger section. Ensure the forcing screw is backed out.
^ Using a wrench on the forcing screw, remove the rear output shaft bushing.





17. Remove the transfer case retaining bolts and washers. Mark the location of any brackets.





Notice: Refer to Machined Surface Damage Notice in Service Precautions.

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





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





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





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





23. Remove the oil pump wear sleeve, only if worn or damaged.





24. Remove the rear output shaft rear bearing retaining ring.





25. Remove the rear output shaft rear bearing.





26. Remove the rear output shaft speed sensor reluctor wheel.





27. Remove the magnet.





28. Disconnect the oil pump suction pipe from the oil pump screen.
29. Remove the oil pump screen from the front case half.
30. Remove the oil pump suction pipe from the oil pump inlet hole.
31. Remove the oil pump suction pipe O-ring from the oil pump.





32. Remove the oil pump wave spring.

33. Remove the oil pump assembly.





34. Remove the oil pump seal.
35. Remove the rear output shaft retaining ring.





36. Remove the drive sprocket retaining ring.





37. Remove the driven sprocket retaining ring.





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

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