1 Thru 32

Transfer Case Disassemble





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





4. Remove the left rear speed sensor.
5. Remove the right rear speed sensor.





6. Remove the front speed sensor.





7. Remove the vent tube (only if damaged).





8. Remove the rubber plug.





9. Remove Ihe front output shaft dust seal.





Notice: Do not damage the sealing surfaces of the transfer cases or the shafts when prying the seals for removal. Damaging the sealing surface may cause leakage or require replacement of the damaged component.

10. Remove the front output shaft seal.





Notice: Do not damage the sealing surfaces of the transfer cases or the shafts when prying the seals for removal. Damaging the sealing surface may cause leakage or require replacement of the damaged component.

11. Remove the input shaft seal.





Notice: Do not damage the sealing surfaces of the transfer cases or the shafts when prying the seals for removal. Damaging the sealing surface may cause leakage or require replacement of the damaged component.

12. Remove the rear output shaft seal.





13. Inspect the rear bushing for scoring or wear.

14. Using the J 4538Q remove the rear bushing.

^ Install the finger section of the J 45380 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 torcing screw remove the rear bushing.





15. Remove the transfer case retaining bolts.





16. Insert a flat bladed screwdriver in the slot on the left side of the transfer case.





17. Insert a flat bladed screwdriver in the slot on the right side of the transfer case
18. Apply equal pressure on both of the screwdrivers in a downward motion and separate the front and rear case halves.





19. Insert a pair of snap ring pliers in the slot.
20. Using the snap ring pliers, open the retaining ring for the rear output shaft bearing.





21. Remove the rear case from the front case.





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





23. Remove the rear output shaft bearing retaining ring.





24. Remove the rear output shaft bearing.





25. Remove the output shaft speed sensor reluctor wheel.





26. Remove the magnet.





27. If 1st design, disconnect the oil pump suction pipe from the oil pump screen.

28. If 1st design, remove the oil pump screen from the front case half.

29. If 1st design, remove the oil pump suction pipe from the oil pump inlet hole.





30. If 2nd design, remove the oil pump suction pipe assembly. Do not remove the screen from the pipe.





31. Remove the oil pump assembly.





32. Remove the oil pump pick up tube seal.