Disassembly
Special Tools:
Special Tool(s)
Disassembly
1. Remove the transfer case.
2. Using the special tool, secure the transfer case to a work bench.
3. Using a suitable tool, remove the oil seal, if necessary.
4. Remove the coil wire pin from the electrical connector.
1 Remove the wire connector spacer.
2 Remove the coil wire pin.
Use an electrical connector pin extractor tool.
5. CAUTION: Note each sensor wire pin location for correct installation.
Remove the front and rear output shaft speed sensor wire pins from the electrical connector.
^ Use an electrical connector pin extractor tool.
6. Remove the transfer case shift motor.
1 Remove the bolts.
2 Remove the transfer case shift motor.
7. Remove the rear output shaft speed sensor.
1 Remove the bolt.
2 Remove the rear output shaft speed sensor.
8. Remove the front output shaft speed sensor.
1 Remove the bolt.
2 Remove the front output shaft speed sensor.
9. Remove the extension housing.
1 Remove the bolts.
2 Remove the extension housing.
10. Remove and discard the sealing ring.
11. Remove the tone wheel spacer and the tone wheel.
12. NOTE: Lift up on the output shaft while removing the snap ring.
Remove the snap ring.
13. NOTE: It is normal to find metal shavings after removing the self-tapping transfer case bolts.
Remove the 20 bolts.
14. Separate the transfer case halves.
^ Use the pry bosses to separate the case halves.
15. Remove the coil, if necessary.
1 Remove the nuts.
2 Remove the coil.
16. Using the special tools, remove the rear output shaft support bearing, if necessary.
17. Using the special tools, remove the front output shaft rear bearing, if necessary.
18. Remove the snap ring.
19. Remove the thrust bearing assembly.
1 Remove the thick thrust bearing race.
2 Remove the thrust bearing.
3 Remove the thin thrust bearing race.
20. Remove the lockup shift fork spring.
21. Remove the cam/coil housing.
22. Remove the steel balls and the cam.
1 Remove the steel balls.
2 Remove the cam.
23. Remove the wave spring.
24. Remove and discard the snap ring.
25. CAUTION: When removing or installing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack upon removal. Set the clutch pack assembly on the bench in the same position as located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem can occur.
Remove the clutch pack assembly
26. Remove the front output shaft tone wheel.
27. Remove the drive chain assembly and the sprockets as an assembly.
28. Remove the thrust bearing assembly.
1 Remove the thrust washer.
2 Remove the thrust bearing.
3 Remove the thrust washer.
29. Remove the lockup collar and assembly and the lockup fork as an assembly.
30. Remove and clean the oil pan magnet.
31. Remove the oil pump assembly and the output shaft as an assembly.
32. Remove the reduction shift fork assembly and the reduction hub as an assembly.
33. Remove the shift fork shaft.
34. WARNING: Do not disassemble the shift cam assembly.
Remove the shift cam assembly.
35. Using the special tool, remove the oil seal.
36. Remove the front planet.
1 Depress the snap ring.
2 Remove the front planet.
37. Using a drift and a hammer, remove the needle bearing, if necessary.
38. If front planet support bearing removal is necessary, remove the snap ring.
39. Using a suitable press and the special tool, remove the front planet support bearing.
40. Remove the ring gear, if necessary.
1 Remove the snap ring.
2 Remove the ring gear.
41. Remove the snap ring.
42. CAUTION: Do not let the front output shaft fall when removing the snap ring.
Remove the front output shaft.
1 Remove the snap ring.
2 Remove the front output shaft.
43. Using the special tools, remove the front output shaft support bearing, if necessary.
44. Using the special tools, remove the oil seal.
45. Using a suitable tool, remove the shifter shaft seal, if necessary.
46. Remove the dust shield, if necessary.