Disassembly

DISASSEMBLY / NV231 Transfer Case
Position transfer case on shallow drain pan. Remove drain plug and drain lubricant remaining in case.


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






3. If the vehicle is equipped with an automatic transmission, remove the output shaft rear slinger using Puller MD-998056-A.






4. If the vehicle is equipped with a manual transmission, 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.






5. Use a suitable pry tool, or a slide hammer mounted screw, to remove the seal from the rear retainer.






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






9. Remove rear retainer from rear case half.
10. Remove the remaining output shaft bearing snap-ring.






11. 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 off the output shaft.






12. Remove pick-up tube O-ring from oil pump, if necessary. Do not disassemble the oil pump, it is not serviceable.








COMPANION FLANGE AND RANGE LEVER
1. Remove transfer case position sensor.






2. Install two bolts partially into the propeller shaft companion flange, 180° from each other.
3. Install the rectangular end of the Flange Holder C-3281 over the bolts to hold the companion flange stationary and remove the nut holding the companion flange to the output shaft.






4. Use Remover C-452 to remove the companion flange.
5. Remove seal washer from front output shaft. Discard washer as it should not be reused.






6. Remove the bolt that attaches the range lever to sector shaft. Then move sector to neutral position and remove range lever from shaft.

NOTE: Be sure to note the orientation of the range lever (lever up or down) so that it may be re-installed in the same direction.



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.






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.
4. Remove rear case from front case.






5. Remove oil pickup tube from rear case.






6. Remove mode fork spring.






7. Pull front output shaft upward and out of front output shaft bearing.
8. Remove front output shaft and chain.



SHIFT FORKS AND MAINSHAFT
1. Remove mainshaft from mode sleeve and input gear pilot bearing.






2. Remove detent plug, O-ring, detent spring and detent plunger.






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






4. Remove range fork and sleeve as an assembly. Note fork position for installation reference.






5. Remove shift sector from front case.






6. Remove the shift sector shaft seal.






7. Remove the shift sector shaft bearing with an appropriate socket.








MAINSHAFT
1. Remove mode hub retaining ring with heavy duty snap-ring pliers.






2. Slide mode hub off mainshaft.






3. Slide drive sprocket off mainshaft.







INPUT GEAR AND LOW RANGE GEAR
1. Remove front bearing retainer attaching bolts.






2. Remove front bearing retainer. Pry retainer loose with pry tool positioned in slots at each end of retainer.
3. Remove front bearing retainer.






4. Remove input gear retaining ring with heavy duty snap-ring pliers






5. Place front case in horizontal position. Then remove input gear and low range gear as an assembly. 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.






2. Remove retainer.






3. Remove front tabbed thrust washer.






4. Remove input gear.






5. Remove rear tabbed thrust washer from low range gear.