Disassembly
GENERAL NOTES1. Disassemble the transfer case in a clean area to prevent entry of dirt into the mechanisms.
2. Use only plastic hammers when applying force to separate the light alloy case joints.
3. Several parts look alike; organize them so they do not get mixed up.
PROCEDURE
1. Drain the transfer case oil into a suitable container.
2. Disassemble in the order shown in the illustration, referring to the following notes:
Transfer Case (5)
^ Using a plastic hammer, remove the chain cover from the transfer case.
Bearing (8)
^ Remove the bearing using the Special Service Tool (SST).
NOTE: SST number: 49 H033 101 Step Plate Adapter Set
2W-4W Shift Fork And Lockup Assembly (11, 12)
^ Remove the 2W-4W lockup assembly and 2W-4W shift fork as an assembly.
Chain, Drive Sprocket And Front Drive Sprocket (15, 16, 17)
^ Remove the chain, drive sprocket and front drive sprocket as an assembly.
Rear Output Shaft, Pump Assembly And Oil Pump Filter (19, 20, 21)
1. Remove the rear output shaft, pump assembly and oil filter as an assembly.
2. Remove the oil pump assembly from the rear output shaft.
Oil Pump Drive Pin (22)
1. Measure and record the height of the oil pump drive pin prior to removal.
2. Remove the oil pump drive pin.
H-L Shift Fork And H-L Hub (25, 26)
^ Remove the H-L shift fork and H-L hub as an assembly.
Front Adapter, Planet Carrier And Input Shaft (29)
1. Remove the bolts from front adapter, planet carrier and input shaft.
2. Remove the front adapter, planet carrier and input shaft as an assembly.
Front Adapter (31)
1. Expand the tanged snap ring in the front adapter.
2. With the input shaft against a work bench, push down on the front adapter.
3. Lift the input shaft and planet carrier from the front adapter.
Planet Carrier (34)
^ Separate the planet carrier from the input shaft.
Ball Bearing (36)
^ Remove the ball bearing using a press and Pinion Bearing Cone Remover D79L-4621-A, or equivalent.
Needle Bearing And Bearing Sleeve (41)
1. Position the input shaft on the SSTs. (49 UN01 036 and 49 HO27 002.)
2. Insert Input Shaft Bearing Remover T91T-7127-A, or equivalent on top of the bearing cage.
3. Tighten the actuator pin until it stops, then press the bearing and sleeve out.
Shift Shaft Lever (42)
1. Move the shift shaft lever to the 4L position, then up two detents to the 4H position. Mark the transfer case in relation to the position of the shift shaft lever.
2. Remove the nut and shift shaft lever.
Shift Shaft (44)
1. Remove the clip from the shift shaft.
2. Pry the shift shaft out of the transfer case.
3. Remove the O-ring from the second groove in the shift shaft. Discard the O-ring.
Ring Gear (48)
^ Use a press to remove the ring gear.
NOTE: Note the relation of the serration to the chamfered pilot diameter during removal.
Front Output Shaft Bearing (Transfer Case Side) (50)
1. Remove the snap ring.
2. Remove the front output shaft bearing using a drift and the SST.
NOTE: SST number: 49 H033 101 Step Plate Adapter Set
Front Output Shaft Bearing (Chain Cover Side) (51)
^ Remove the front output shaft bearing using the SSTs.