Disassembly

DISASSEMBLY
COMPANION FLANGE

NOTE: Position transfer case on work bench with rear or cover side up. Use wooden blocks under front to keep assembly level.

1. Remove nut and washer.
2. Pull companion flange.
3. Remove oil seal.





4. If installed, remove two plugs from cover.

EXTERNAL ELECTRIC SHIFT
On electric shift units, remove components as follows.
1. Remove bolt (1).
2. Remove three bolts (3).
3. Remove sensor and harness bracket.
4. Remove speed sensor assembly.





5. Remove motor assembly.

COVER ASSEMBLY
1. Remove nine bolts (1). This will free wiring harness clip and identification tag. Use care not to lose identification tag. It contains information required for ordering replacement parts.
2. Pry at the bosses provided on the cover and transfer case to break the sealant bond loose. Then, lift cover assembly straight up to remove.
3. On electric shift units, remove oil seal (5), bearing, three nuts and clutch coil assembly.
4. Remove snap ring and pull ball bearing from cover. This will free speedo gear.
5. Pull needle bearing from cover.
6. Pull oil seal (15) from cover.
7. Remove magnet from slot in case.
8. Remove return spring from rail shaft.





9. Scrap and clean sealant from mating faces of cover and transfer case. Use care not to damage metal faces or allow scrapings to fall into transfer case.

LOCK SHIFT
1. From electric shift only, remove retaining ring and slide clutch housing from shift collar hub.
2. Remove shift collar hub from output shaft.
3. Together, slide 2W-4W lockup assembly and lockup fork from output shaft and rail shaft. Separate assemblies and remove rail shaft.
4. To disassemble 2W-4W lockup assembly, remove snap ring, lockup hub and return spring from lockup collar.





5. One-piece, plastic lockup fork replaces earlier fork assembly with metal fork and separate roller parts.

CHAIN DRIVE
1. Remove snap ring and spacer from output shaft (front).





2. Together, slide drive sprocket, driver sprocket and drive chain from output shafts (rear and front). Separate sprockets and chain when out of assembly.

OIL PUMP
1. Remove four bolts (2) and retainer. Slide rear pump cover off output shaft.
2. Loosen hose clamp and separate hose coupling from pump housing. Slide pump housing off output shaft.
3. Remove hose clamp, hose coupling and strainer.
4. Remove two pump pins and spring from output shaft.





5. Slide front pump cover off output shaft and remove output shaft.

REDUCTION SHIFT
1. Remove reduction hub and reduction shift fork assembly from transfer case.
2. Remove two facings from shift fork assembly.





3. Disassemble fork assembly only if parts replacement is required. Cut plastic retainer to remove, freeing pin and cam roller.

FRONT OUTPUT SHAFT
1. Hold yoke and remove nut and washer. Pull yoke assembly and oil seal.
2. Press deflector from yoke only if replacement is required.





3. Remove output shaft.

ADAPTER, INPUT SHAFT AND GEAR CARRIER
1. Remove breather.
2. Remove six bolts (2). Carefully pry front adapter up to break sealant band with transfer case. Use care not to damage adapter or case.
3. Remove adapter assembly, input shaft assembly and gear carrier assembly as an assembled group.
4. Holding end of input shaft on workbench press down on adapter while expanding long ends of snap ring.
5. Remove snap ring and pump oil seal from front adapter. Remove pin only if replacement is required.
6. Remove retaining ring (8). Pull bearing and thrust washer from end of input shaft assembly. Remove input shaft assembly from gear carrier assembly.
7. To disassemble input shaft assembly, pull sleeve bearing and needle bearing from input shaft.





8. Remove retaining ring (16), thrust plate end sun gear from planet carrier assembly.

SHIFT CAM (ELECTRIC PARTS)
1. Remove electric shift cam group (1 through 4) from transfer case as an assembly.
2. Slide electric shift cam off shift shaft.
3. Clamp retainer end of shift shaft. Keeping fingers away from spring ends, pry torsion spring out of engagement with shaft drive tang using a screwdriver.





4. Remove torsion spring and spacer from shift shaft.

CASE ASSEMBLY
1. Pull oil seal.
2. Remove retaining ring and pull ball bearing.
3. Remove dowel pins from transfer case only if they are loose or damaged.





4. Press ring gear out of transfer case only if ring gear must be replaced.