Steps 1 - 30

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

Important:
^ The following service procedure will cover light duty, heavy duty, and super duty versions of this transfer case.
^ The front output shaft seal and the input shaft seal only require replacement if faulty, or if removing the front output shaft or input gear.





1. Remove the drain plug (2) and the till plug (1).

2. Drain the fluid from the transfer case.





3. Remove the rear output shaft seal.





4. Inspect the rear output shaft bushing for scoring or wear.
5. Remove the rear output shaft bushing using the J 45380.
^ 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 forcing screw, remove the rear output shaft bushing.





6. Remove the access hole plug.





7. Remove the transfer case vehicle speed sensor.





8. Remove the encoder motor assembly.





9. Remove the vent tube ONLY if the vent tube elbow is damaged.





Important: The magnesium transfer cases are using new style bolts that have a cup style washer The cup washer is only available with the bolt. It the cup washer is not damaged, the bolt can be used again.

10. Remove the transfer case retaining bolts, the washers, and the brackets.
11. Mark the location of the brackets for correct assembly.





12. Insert a screwdriver into the slot on the left side of the transfer case.





13. Insert a screwdriver into the slot on the right side of the transfer case.
14. With equal pressure applied on each screwdriver, separate the front half and the rear half.





15. Using a pair of snap ring pliers, release the outside retaining ring for the rear output shaft bearing.





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





17. Remove the rear output shaft bearing retaining ring.





18. Remove the rear output shaft bearing.





19. Remove the speed reluctor wheel.





20. Remove the oil pump suction pipe from the oil pump assembly.
21. Remove the oil pump screen from the front case half.
22. Disconnect the connector between the oil pump suction pipe to the oil pump screen.





23. Remove the magnet.





24. Remove the oil pump assembly.





25. Remove the O-ring seal for the oil pump suction pipe.





26. Remove the shift fork shaft detent spring.





27. Remove the driven sprocket retaining ring.





28. Remove the drive sprocket retaining ring.





Important: If the drive chain and sprockets are to be reused, mark the position drive chain to the drive sprockets in order to ensure that any wear patterns will be matched for proper installation.

29. Remove the drive chain and the sprockets from the mainshaft and the front output shaft.





30. Remove the two/four wheel drive synchronizer gear from the drive sprocket sleeve.