Disassembly

1. Remove the transfer case and place on a workbench.

CAUTION: Seals are damaged upon removal. New seals are required after removal.





2. Remove the drain plug and drain the fluid.





3. Mark the rear transfer case flange and the rear output shaft for correct reassembly.





4. Install Companion Flange Holding Tool to the rear output flange.





5. Remove the rear output flange.
(1) Remove the rear output flange nut.
(2) Remove the rear output flange washer.
(3) Remove the rear output flange seal.
(4) Remove the rear output flange.





6. Place the transfer case in Bench Mounted Holding Fixture and remove 17 bolts from the front case half and the rear case half.





7. Insert a pry bar and separate the front and rear case halves.





8. Remove the rear output shaft and ring gear from the rear case half.
(1) Place the rear half of the case in Bench Mounted Holding Fixture.
(2) Open the retaining ring.
(3) Remove the rear output shaft and rear gear.

CAUTION: Do not remove the bearing from the rear output shaft.





9. Remove the output shaft bearing and the speedometer tone wheel.
(1) Remove the output shaft bearing.
(2) Remove the speedometer tone wheel.





10. Remove the rear output shaft seal and the bearing.
(1) Pry out the rear output shaft seal.
(2) Pull out the rear output shaft bearing.





11. Remove the ring gear from the rear output shaft.
(1) Remove the retaining ring.
(2) Remove the ring gear from the rear output shaft.





12. Place the front case half in Bench Mounted Holding Fixture and remove the planetary gear thrust washer.





13. Remove the planetary assembly.





14. Remove the sun gear thrust washer.





15.Remove the viscous clutch with the driven sprocket and the drive chain.

NOTE: Do not remove the viscous clutch bushing or pinion bearing. Replace as part of the viscous clutch assembly.





16. Press the sun gear shaft bearing off the sun gear.





17.Remove the input shaft.

NOTE: Do not remove the front case half input shaft bushing. Replace as part of the front case half.





18 Remove the four bolts and the two chain snubbers





19. Remove the front output shaft.
(1) Remove the front output shaft retaining ring.
(2) Remove the front output shaft with a soft face hammer.





20. Remove the front output shaft bearing with Bearing Remover and Impact Slide Hammer.





21. Turn the transfer case front half over in Bench Mounted Holding Fixture and pry out the input shaft seal.





22. Pry out the front output shaft seal.