Disassembly

Fig. 48 Exploded view of New Process model 242 transfer case:

1. Remove fill and drain plugs.
2. Remove front yoke retaining nut, then the yoke and seal. The yoke seal, washer and nut are not reusable and must be discarded at this time.
3. Shift transfer case control lever to four-wheel low lock position.
4. Remove extension housing attaching bolts and housing. Do not pry housing from case. If necessary, tap housing off with a soft-faced mallet.
5. Remove and discard rear bearing snap ring from mainshaft.
6. Remove rear retainer attaching bolts, then position a screwdriver under each tab on retainer housing and carefully pry retainer from case. Do not pry against sealing surfaces.
7. Remove rear case-to-front case attaching bolts, then carefully separate cases using screwdrivers inserted in case slots. Do not pry against sealing surfaces.
8. Remove oil pump and rear case as an assembly.
9. Slide oil pickup screen from case, then remove oil pump, pickup tube and screen.
10. Remove pickup tube and screen from oil pump, then remove and discard pickup tube O-ring from pump.
11. Disassemble oil pump as follows:
a. Remove and discard oil pump seal.
b. Mark relationship between pump housings for assembly reference.
c. Remove attaching screws and separate pump halves.
d. Note position of pump gears for assembly reference, then remove gears from housing.
12. Remove magnet from case.
13. Remove drive sprocket snap ring, then the drive sprocket and chain.
14. Remove front output shaft.
15. Remove shift lever-to-sector shaft nut, then the shift lever.
16. Remove shift detent plug, spring and plunger from case.
17. Remove seal plug from low range fork lockpin access hole, then align low range fork lockpin with access hole.
18. Remove low range fork lockpin using an screw/pin extracting tool.
19. Pull shift rail straight up and out of shift fork.
20. Remove mainshaft and mode fork as an assembly from front case.
21. Remove mode shift sleeve and mode fork assembly from mainshaft.
22. Note position of mode sleeve in fork for assembly reference, then remove sleeve from fork.
23. Remove intermediate clutch shaft snap ring and thrust ring, then the clutch shaft from mainshaft.
24. Remove differential snap ring, then the differential from mainshaft.
25. Remove differential needle bearings and bearing thrust washers from mainshaft.
26. Slide low range fork pin out of shift sector, then remove low range fork, hub and sector.
27. Remove sector shaft bushing and O-ring from case.
28. Remove front bearing retainer attaching bolts, then carefully pry front bearing retainer from front case using a screwdriver positioned into slots cast in retainer.
29. Remove input gear snap ring, then press input and low range gear assembly from input gear bearing using tool No. J-29170 or equivalent.
30. Remove snap ring, then the input gear retainer, thrust washers and input gear from low range gear. The low range annulus gear is not serviceable. If gear is damaged, gear and front case must be replaced as an assembly.
31. Remove and discard oil seals from rear retainer, extension housing, oil pump and case halves.
32. Disassemble differential as follows:
a. Mark differential halves for assembly reference.
b. Remove case attaching bolts, then carefully remove upper case. Pry case halves at slots provided.
c. Remove planetary gear thrust washers and gears from lower case half.
d. Remove mainshaft gear and sprocket gear from lower case half, noting their positions for assembly reference.