Transfer Case - Disassembly

DISASSEMBLY





1. Place the transfer case in a shallow pan and remove the fill (1) and drain (2) plugs to drain the remainder of the fluid.




2. Using Holder C-3281 (1), remove the rear flange (2) nut.




3. Remove the rear output flange (1) from the main shaft (2). If necessary, use a suitable 2 or 3 jaw puller to remove the output flange.




4. Remove the bolts (1) holding the shift motor and mode sensor assembly (2) to the transfer case.




5. Remove the shift motor and mode sensor assembly (1) from the shift sector (2) and the transfer case (3).




6. If necessary, remove the bolts holding the transfer case damper to the transfer case and remove the damper.
7. Remove the bolts (3) holding the rear cover (2) onto the rear housing (1).




NOTE: Use the pry slots provided and take care not to damage the sealing surface.

8. Remove the rear cover (1) from the rear housing (2).




NOTE: Rotate the sector upward to ease the removal of the roll-pin.

9. Using a suitable punch, remove the roll-pin (2) holding the sector roller (4) to the shift rail (3).




10. Remove the sector roller (1) from the shift rail (2).




11. Remove the anti-rotation bracket (1) from the shift rail (2).




12. Remove the clutch lever rail plug (1) from the rear housing.




13. Remove the clutch lever rail (2) from the rear housing (1).




14. Remove the oil pump inner rotor (2) from the main shaft (1) and rear housing (3).




15. Remove the oil pump outer rotor (2) from the main shaft (1) and rear housing (3).




NOTE: Pull upward on the main shaft to ease the removal of the main shaft retaining ring.

16. Remove the rear output shaft (1) retaining ring (2).




17. Remove the bolts (2) holding the rear housing (1) to the front housing (3).




NOTE: Some prying may be necessary to break the seal between the front and rear case. Use care to not damage the sealing surfaces.

18. Remove the rear housing (1) from the front housing (2).




19. Remove the clutch lever assembly (1) from the mainshaft and shift rail.




20. Remove the thrust bearing support plate retaining ring (2) from the main shaft (1).




21. Remove the thrust bearing support plate (2) from the main shaft (1).




22. Remove the thrust bearing (2) from the main shaft (1).




23. Remove the clutch pressure plate (2) from the main shaft (1) and clutch assembly.




24. Remove the wave spring (2) from the main shaft (1).




25. Remove the clutch assembly (2) from the main shaft (1).




26. Remove the front drive sprocket retaining ring (2) from the front output shaft (1).




27. Remove the front drive sprocket (1), mainshaft drive sprocket (2), and drive chain (3) as one.




28. Remove the screws (2) holding the chain guide rails (1) to the front housing.




29. Remove the drive chain guides (1) from the transfer case.




30. Remove the mainshaft and differential assembly (1) from the front housing (2).




31. Remove intermediate clutch shaft (2) snap-ring (1).




32. Remove the intermediate clutch shaft thrust ring (1).




33. Remove the intermediate clutch shaft (1).




34. Remove the differential snap-ring (1).




35. Remove the differential assembly (1) from the mainshaft (2).




36. Remove the mode hub (2) and mode hub retainer from the differential assembly (1).




37. Remove the mode hub retainer (1) from the mode hub (2).




38. Remove the range fork and range hub as one.




39. Remove the retaining ring (2) from the front output shaft (1).




40. Remove the front output shaft (2) from the front housing (1) and the front output shaft front bearing.




41. Remove the oil pick-up tube and screen (1) from the rear housing.




42. Remove the oil pick-up tube o-ring (2) from the rear housing (1).




43. Remove the retaining ring (2) from the shift sector shaft (1).




44. Remove the shift sector (2) from the rear housing (1).




45. Remove the input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
46. Remove the retaining ring (2) holding the input gear assembly into the front housing.




47. Remove the input gear and low range planetary assembly (1) from the front housing.




48. Remove the snap-ring (2) holding the input gear (1) into the low range planetary (3).




49. Remove the input gear (1) and lock plate (2) from the low range planetary (3) and remove the lock plate.




50. Remove the top thrust washer (no tabs) (2) from the input gear (1).




51. Remove the bottom thrust washer (3 tabs) (1) from the low range planetary (2).