Disassembly

TRANSFER CASE - NV231

DISASSEMBLY
Position transfer case on shallow drain pan. Remove drain plug and drain lubricant remaining in case.

REAR RETAINER AND OIL PUMP
1. Remove the speedometer adapter.
2. Spread band clamp which holds output shaft boot to the output shaft slinger, or output shaft damper, with a suitable awl, or equivalent.

NOTE: Vehicles built with a 4.OL engine and a manual transmission use a damper weight on the transfer case output shaft. Be sure to identify the transfer case before proceeding.

3. Remove output shaft boot from slinger, or output shaft damper, and output shaft.





4. If the vehicle is not equipped with an output shaft damper, remove the output shaft rear slinger using Puller MD-998056-A (Fig. 3).
5. If the vehicle is equipped with an output shaft damper, use Screws 8421 and the puller yoke and forcing screw from a bolt-grip puller set, such as those used to remove steering wheels and harmonic balancers, to remove the transfer case output shaft damper.





6. Use a suitable pry tool, or a slide hammer mounted screw, to remove the seal from the rear retainer (Fig. 4).





7. Remove the rear output bearing I.D. retaining ring (Fig. 5).
8. Remove the bolts holding the rear retainer to the rear case half.
9. Tap rear retainer with rawhide or rubber mallet to loosen sealer bead.





10. Remove rear retainer from rear case half (Fig. 6).
11. Remove snap-ring holding oil pump in position on output shaft.





12. Disengage oil pickup tube from oil pump and remove oil pump assembly. Remove oil pump by tilting the edge of the oil pump from under the edge of the rear case half and sliding the pump (Fig. 7).





13. Remove pick-up tube O-ring from oil pump (Fig. 8), if necessary. Do not disassemble the oil pump, it is not serviceable.

YOKE AND RANGE LEVER
1. Remove transfer case indicator switch.
2. Remove front yoke nut as follows:
a. Move range lever to 4L position.





b. Then remove nut with socket and impact wrench (Fig. 9).





3. Remove yoke. If yoke is difficult to remove by hand, remove it with bearing splitter, or with standard two jaw puller (Fig. 10). Be sure puller tool is positioned on yoke and not on slinger as slinger will be damaged.
4. Remove seal washer from front output shaft. Discard washer as it should not be reused.





5. Remove nut and washer that attach range lever to sector shaft. Then move sector to neutral position and remove range lever from shaft (Fig. 11).

FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Support transfer case so rear case is facing upward.





2. Remove bolts holding front case to rear case. The case alignment bolts require flat washers (Fig. 12).





3. Loosen rear case with flat blade screwdriver to break sealer bead. Insert pry tool blade only into notches provided at each end of case (Fig. 13).
4. Remove rear case from front case.





5. Remove oil pickup tube from rear case (Fig. 14).





6. Remove mode fork spring (Fig. 15).





7. Pull front output shaft upward and out of front output shaft bearing (Fig. 16).
8. Remove front output shaft and chain.

SHIFT FORKS AND MAINSHAFT





1. Remove detent plug, O-ring, detent spring and detent plunger (Fig. 17).
2. Remove mainshaft from mode sleeve and input gear pilot bearing.





3. Remove mode fork and sleeve as an assembly (Fig. 18). Note position of sleeve for assembly reference. The short side of the sleeve faces upward.





4. Remove range fork and hub as an assembly (Fig. 19). Note fork position for installation reference.





5. Remove shift sector from front case (Fig. 20).





6. Remove shift sector bushing and O-ring (Fig. 21).

MAINSHAFT





1. Remove mode hub retaining ring with heavy duty snap-ring pliers (Fig. 22).





2. Slide mode hub off mainshaft (Fig. 23).





3. Slide drive sprocket off mainshaft (Fig. 24).

INPUT GEAR AND LOW RANGE GEAR





1. Remove front bearing retainer attaching bolts (Fig. 25).





2. Remove front bearing retainer. Pry retainer loose with pry tool positioned in slots at each end of retainer (Fig. 26).
3. Remove front bearing retainer seal. Tap seal out with drift and hammer.





4. Remove input gear retaining ring with heavy duty snap-ring pliers (Fig. 27)





5. Place front case in horizontal position. Then remove input gear and low range gear as an assembly (Fig. 28). Tap gear out of bearing with plastic mallet if necessary.

INPUT AND LOW RANGE GEAR





1. Remove snap-ring that retains input gear in low range gear (Fig. 29).





2. Remove retainer (Fig. 30).





3. Remove front tabbed thrust washer (Fig. 31).





4. Remove input gear (Fig. 32).





5. Remove rear tabbed thrust washer from low range gear (Fig. 33).