Clutch - 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 (2) to the transfer case.





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










6. Remove the bolts holding the rear housing to the front housing.

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

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





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





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





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





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





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










13. Remove the top, outer lugged, clutch plate from the clutch retainer (2).










14. Remove the next (inner teeth) clutch plate (1) from the clutch retainer (2). Continue removing plates until the bottom (outer lugs) clutch plate is removed. Keep the discs in their original sequence if the discs are to be reused.