Transfer Case Disassemble
Transfer Case Disassemble
Special Tools
* J-2619-A - Slide Hammer with Adapter
* J 3289-20 - Holding Fixture
* J 22912-B - Rear Pinion and Axle Bearing Remover
* J 26941 - Bushing and Bearing Remover - 3-4 inch
* J 36825 - Output Shaft Oil Seal Remover - 4WD Models Only
* J 45358 - Case Spreader
* J 45380 - Transfer Case Rear Bushing Remover and Installer
* J 45759 - Assembly Fixture
* J 45849 - Bearing Remover
For equivalent regional tools, refer to Special Tools Tools and Equipment.
1. Mount the J 3289-20 - holding fixtureto a sturdy workbench.
2. Attach the J 45759 - assembly fixtureon the transfer case using the adapter studs. All of the transfer case disassembly procedures can be performed with the case mounted to the J 45759 - assembly fixture.
3. Install the J 45759 - assembly fixture (2) into J 3289-20 - holding fixture (1) and secure with pivot pin.
4. Remove the drain plug. Ensure all of the transfer case fluid is drained out of the transfer case.
Caution:
Refer to Transfer Case Seal Removal Caution Service Precautions.
Note:
The front output shaft seal is a 2 piece internal seal. The inner seal race is a force fit on the front output shaft.
5. Remove the front input shaft seal by inserting a flat-tipped screwdriver behind the inner race of the seal.
6. Pry the inner seal race forward.
7. Using a small pry bar, move the inner seal race forward on the front input shaft.
8. Remove the inner seal race from the front input shaft.
9. Insert a flat-tipped screwdriver or a small pry bar between the lip of the outer lip of the front output shaft seal and the transfer case.
10. Remove the remaining part of the front output shaft seal from the transfer case.
11. Remove the vehicle speed sensor (VSS) with O-ring seal.
Caution:
Refer to Transfer Case Seal Removal Caution Service Precautions.
12. Remove the rear output shaft seal by prying out with a flat-blade screwdriver.
13. Using the J 45380 - bushing remover/installer, remove the rear output shaft bushing.
14. Remove the transfer case retaining bolts and the washers.
15. Mark the location of the brackets.
Caution:
Refer to Machined Surface Damage Caution Machined Surface Damage Caution.
16. Using the J 45358 - case spreaderbetween the tabs on the case halves, shear the sealer holding the case halves together.
17. Using pry bars at each side of the case, remove the case from the locating pins.
18. Remove the rear case half from the front case half. The rear output shaft will come out with the rear case half.
19. Remove the planetary carrier assembly thrust washer.
20. Remove the planetary carrier assembly.
21. Remove the sun gear thrust washer.
22. Remove the front input shaft.
23. If the cup plug in the front output shaft is leaking, remove the plug using a brass drift.
Note:
If the chain and sprockets are to be used again, mark the relationship of the chain to the sprockets in order to mark the wear patterns.
24. Remove the chain with the driven sprocket.
25. Remove the sun gear with the drive gear and viscous coupling. Lift up on the sun gear assembly while tapping down on the input shaft with a soft-face hammer.
26. Using a hydraulic press and J 22912-B - pinion/bearing remover, remove the bearing from the sun gear.
27. Remove the drive gear from the sun gear.
28. Remove the viscous coupling from the sun gear.
29. Remove the input shaft from the front case.
30. Using the J-2619-A - slide hammer (1) and the J 36825 - seal remover - 4WD (2), remove the input seal.
1. Poke a hole in the seal using a very sharp punch.
2. Thread the J 36825 - seal remover - 4WD (2) into the hole.
31. Remove the input shaft bushing from the front case using a hammer and brass drift.
32. Using a brass drift, remove the front output shaft bearing from the front case half.
33. If necessary, remove the vent from the front case half.
34. Remove the rear output shaft from the rear case half.
1. Spread the rear output shaft rear bearing outer retaining ring (1).
2. Using a soft-face hammer, tap on the end of the rear output shaft.
35. Remove the annulus gear retaining ring.
36. Remove the rear output shaft from the annulus gear.
37. Inspect the bearing in the rear output shaft. Refer to Transfer Case Cleaning and Inspection Transfer Case Cleaning and Inspection.
38. If the bearing is faulty, remove the bearing using the J 45849 - bearing remover.
1. Install the finger part of the J 45849 - bearing removerin the bearing.
2. Thread the driver part into the fingers.
3. Remove the bearing from the fingers by squeezing the fingers together.
39. Remove the retaining ring for the rear output shaft bearing and the speed reluctor wheel.
40. Using a hydraulic press and the J 22912-B - pinion/bearing remover, remove the speed reluctor wheel and the rear output shaft bearing.
Do not use the speed reluctor wheel again.
41. Remove the rear bearing for the front output shaft from the rear case, using the J 26941 - bushing/bearing remover (1) and the J-2619-A - slide hammer (2).