Part 1

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).