Disassembly

1. Remove fill and drain plugs and drain lubricant from transfer case.
2. Remove front and rear yoke nuts and seal washers. Discard washers.

Fig. 19 Exploded view of New Process model 229 transfer case:

3. Mark relationship between front and rear yokes and propeller shafts for reference during reassembly, then remove yokes.
4. Support transfer case on wood blocks with V-notches cut in blocks to provide clearance for front case mounting studs.
5. Mark relationship between rear retainer and rear case for reference during reassembly, then remove rear retainer attaching bolts and pry retainer off case by inserting screwdrivers in slots provided in case.

Fig. 20 Differential shims & speedometer drive gear replacement:

6. Remove differential shim(s) and speedometer drive gear from rear output shaft.
7. Remove rear case to front case attaching bolts, then separate case halves by prying with screwdrivers, in slots at case ends.

Fig. 21 Front output shaft thrust bearing replacement:

8. Remove thrust bearings and races from front output shaft. Note position of bearing and races for reference during reassembly.
9. Remove oil pump from rear output shaft, noting position of oil pump for reference during reassembly.
10. Remove mainshaft pilot bearing rollers (15) from shaft, or from coupling if rollers fell off during rear output shaft removal.

Fig. 22 Viscous coupling replacement:

11. Remove O-ring from end of mainshaft, then the viscous coupling from mainshaft and side gear.
12. Remove front output shaft, driven sprocket and drive chain assembly. To ease removal, lift assembly upward, tilt front shaft towards mainshaft and slide chain off drive sprocket.
13. Remove front output shaft front thrust bearing from case or shaft, then the drive chain from front output shaft and sprocket.
14. Remove snap ring retaining driven sprocket to front output shaft, then remove sprocket from shaft. Mark relationship between shaft and sprocket for reference during reassembly.

Fig. 23 Mainshaft assembly replacement:

15. Remove mainshaft, side gear, clutch gear, drive sprocket and spline gear as an assembly.

Fig. 24 Mode fork, shift fork & clutch sleeve removal:

16. Remove mode fork, shift rail and clutch sleeve as an assembly. Mark relationship between sleeve and fork for reference during reassembly and remove sleeve from fork.
17. Remove locking fork, clutch sleeve, fork brackets and fork springs as an assembly, then disassemble components for cleaning and inspection.
18. Remove range sector detent screw, spring, plunger and ball.
19. Disengage low range fork lug from range sector slot.
20. Remove annulus gear snap ring and thrust washer, then the annulus gear, range fork and rail as an assembly. Disassemble components for cleaning and inspection.
21. Remove thrust washer from planetary assembly hub, then remove planetary gear assembly.
22. Remove mainshaft thrust bearing from input gear, then the input gear and input gear thrust bearing race.
23. Remove range sector and operating lever attaching nut and lockwasher, then remove lever, range sector and shaft, range sector O-ring and retainer.
24. Remove sprocket clutch gear and side gear from mainshaft.
25. Remove needle bearings (82) and two bearing spacers from mainshaft. Note position of spacers for reference during reassembly.

Fig. 25 Side & clutch gear replacement:

26. Remove spline gear and thrust washer, side gear, and clutch gear and thrust washer from sprocket carrier and sprocket.
27. Remove clutch gear and thrust washer from side gear.
28. Remove one sprocket carrier snap ring, then remove drive sprocket from carrier.
29. Remove three bearing spacers and all sprocket carrier needle bearings from carrier. The sprocket carrier and mainshaft needle bearings are different sizes and care must be taken to avoid mixing them.
30. Remove rear output bearing and rear yoke seal from retainer. Note position of bearing for reference during reassembly.
31. Remove input gear and front yoke seals from case. Pry seals from case using a screwdriver.